Method for assembling a cartridge for a smoking article

ABSTRACT

The present disclosure relates to systems, apparatuses, and methods for assembling cartridges for aerosol delivery devices. The cartridges may be assembled by transporting carriages between various substations at which parts are added to a base. In another assembly method, the base may be moved between a plurality of robots which direct the base downwardly into contact with components to couple the components therewith. An inspection system may inspect the cartridges at various stages of completion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.14/227,159, filed Mar. 27, 2014, which claims the benefit of U.S.Provisional Application No. 61/939,446, filed Feb. 13, 2014, each ofwhich is entirely incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to a cartridge for aerosol deliverydevices such as smoking articles, and more particularly to methods forassembling a cartridge for smoking articles including an atomizer. Theatomizer may be configured to heat an aerosol precursor, which may bemade or derived from tobacco or otherwise incorporate tobacco, to forman inhalable substance for human consumption.

BACKGROUND

Cigarettes, cigars and pipes are popular smoking articles that employtobacco in various forms. For example, a traditional type of cigarettehas a substantially cylindrical rod-shaped structure and includes acharge, roll or column of smokable material, such as shredded tobacco(e.g., in cut filler form), surrounded by a paper wrapper, therebyforming a so-called “smokable rod”, “tobacco rod” or “cigarette rod.”Normally, such a cigarette has a cylindrical filter element aligned inan end-to-end relationship with the tobacco rod. Preferably, a filterelement comprises plasticized cellulose acetate tow circumscribed by apaper material known as “plug wrap.” Preferably, the filter element isattached to one end of the tobacco rod using a circumscribing wrappingmaterial known as “tipping paper.” It also has become desirable toperforate the tipping material and plug wrap, in order to providedilution of drawn mainstream smoke with ambient air. Descriptions ofcigarettes and the various components thereof are set forth in TobaccoProduction, Chemistry and Technology, Davis et al. (Eds.) (1999); whichis incorporated herein by reference in its entirety. A traditional typeof cigarette is employed by a smoker by lighting one end of the tobaccorod. The smoker then receives mainstream smoke into his/her mouth bydrawing on the opposite end (e.g., the filter end or mouth end) of theburning cigarette.

Through the years, efforts have been made to improve upon thecomponents, construction and performance of smoking articles thatrequire combustion of tobacco for smoke generation. Many of theimprovements that have been proposed purportedly attempt to provide thesensations associated with cigarette, cigar or pipe smoking, but withoutdelivering considerable quantities of incomplete combustion andpyrolysis products that result from burning tobacco. See, for example,the various references described, discussed, or referenced in U.S. Pat.No. 7,753,056 to Borschke et al.; which is incorporated herein byreference in its entirety.

Certain types of cigarettes that employ carbonaceous fuel elements havebeen commercially marketed under the brand names “Premier” and “Eclipse”by R. J. Reynolds Tobacco Company. See, for example, those types ofcigarettes described in Chemical and Biological Studies on New CigarettePrototypes that Heat Instead of Burn Tobacco, R. J. Reynolds TobaccoCompany Monograph (1988) and Inhalation Toxicology, 12:5, p. 1-58(2000). Additionally, a similar type of cigarette recently has beenmarketed in Japan by Japan Tobacco Inc. under the brand name “Steam HotOne.” Furthermore, various types of smoking products incorporatingcarbonaceous fuel elements for heat generation and aerosol formationrecently have been set forth in the patent literature. See, for example,the types of smoking products proposed in U.S. Pat. No. 7,836,897 toBorschke et al.; U.S. Pat. No. 8,469,035 to Banerjee et al. and U.S.Pat. No. 8,464,726 to Sebastian et al.; US Pat. Pub. Nos. 2012/0042885to Stone et al.; 2013/0019888 to Tsuruizumi et al; 2013/0133675 toShinozaki et al. and 2013/0146075 to Poget et al.; PCT WO Nos.2012/0164077 to Gladden et al.; 2013/098380 to Raether et al.;2013/098405 to Zuber et al.; 2013/098410 to Zuber et al. and 2013/104914to Woodcock; EP 1808087 to Baba et al. and EP 2550879 to Tsuruizumi etal.; which are incorporated herein by reference in their entirety.

In recent years, there have been proposed numerous smoking products,flavor generators and medicinal inhalers that utilize electrical energyto heat and vaporize volatile materials, or otherwise attempt to providemany of the sensations of smoking, without burning tobacco to anysignificant degree. See, for example, the various types of aerosolgeneration devices described, discussed, or referenced in U.S. Pat. No.7,726,320 to Robinson et al., U.S. patent application Ser. No.13/826,929, filed Mar. 14, 2013, to Ampolini et al., Ser. No.14/011,992, filed Aug. 28, 2013, to Davis et al., and Ser. No.14/170,838, filed Feb. 3, 2014, to Bless et al.; which are incorporatedherein by reference in their entireties.

In this regard, certain tobacco products that have employed electricalenergy to produce heat for smoke or aerosol formation, and inparticular, certain products that have been referred to as electroniccigarette products, have become commercially available throughout theworld. Representative products that resemble many of the attributes oftraditional types of cigarettes, cigars or pipes have been marketed asACCORD® by Philip Morris Incorporated; ALPHA™ JOYE 510™ and M4™ byInnoVapor LLC; CIRRUS™ and FLING™ by White Cloud Cigarettes; BLU™ byLorillard Technologies, Inc.; COHITA™, COLIBRI™, ELITE CLASSIC™,MAGNUM™, PHANTOM™ and SENSE™ by Epuffer® International Inc.; DUOPRO™,STORM™ and VAPORKING® by Electronic Cigarettes, Inc.; EGAR™ by EgarAustralia; eGo-C™ and eGo-T™ by Joyetech; ELUSION™ by Elusion UK Ltd;EONSMOKE® by Eonsmoke LLC; FIN™ by FIN Branding Group, LLC; SMOKE® byGreen Smoke Inc. USA; GREENARETTE™ by Greenarette LLC; HALLIGAN™,HENDU™, JET™, MAXXQ™ PINK™ and PITBULL™ by Smoke Stik®; HEATBAR™ byPhilip Morris International, Inc.; HYDRO IMPERIAL™ and LXE™ from Crown7;LOGIC™ and THE CUBAN™ by LOGIC Technology; LUCI® by Luciano Smokes Inc.;METRO® by Nicotek, LLC; NJOY® and ONEJOY™ by Sottera, Inc.; NO. 7™ by SSChoice LLC; PREMIUM ELECTRONIC CIGARETTE™ by PremiumEstore LLC; RAPPE-MYSTICK™ by Ruyan America, Inc.; RED DRAGON™ by Red Dragon Products,LLC; RUYAN® by Ruyan Group (Holdings) Ltd.; SF® by Smoker FriendlyInternational, LLC; GREEN SMART SMOKER® by The Smart Smoking ElectronicCigarette Company Ltd.; SMOKE ASSIST® by Coastline Products LLC; SMOKINGEVERYWHERE® by Smoking Everywhere, Inc.; V2CIGS™ by VMR Products LLC;VAPOR NINE™ by VaporNine LLC; VAPOR4LIFE® by Vapor 4 Life, Inc.; VEPPO™by E-CigaretteDirect, LLC; VUSE® by R. J. Reynolds Vapor Company; MisticMenthol product by Mistic Ecigs; and the Vype product by CN CreativeLtd. Yet other electrically powered aerosol delivery devices, and inparticular those devices that have been characterized as so-calledelectronic cigarettes, have been marketed under the tradenames COOLERVISIONS™; DIRECT E-CIG™; DRAGONFLY™; EMIST™; EVERSMOKE™; GAMUCCI®;HYBRID FLAME™; KNIGHT STICKS™; ROYAL BLUES™; SMOKETIP®; SOUTH BEACHSMOKE™.

Additional manufacturers, designers, and/or assignees of components andrelated technologies that may be employed in aerosol delivery deviceinclude Shenzhen Jieshibo Technology of Shenzhen, China; Shenzhen FirstUnion Technology of Shenzhen City, China; Safe Cig of Los Angeles,Calif.; Janty Asia Company of the Philippines; Joyetech ChangzhouElectronics of Shenzhen, China; SIS Resources; B2B InternationalHoldings of Dover, Del.; Evolv LLC of OH; Montrade of Bologna, Italy;Shenzhen Bauway Technology of Shenzhen, China; Global Vapor TrademarksInc. of Pompano Beach, Fla.; Vapor Corp. of Fort Lauderdale, Fla.;Nemtra GMBH of Raschau-Markersbach, Germany, Perrigo L. Co. of Allegan,Mich.; Needs Co., Ltd.; Smokefree Innotec of Las Vegas, Nev.; McNeil ABof Helsingborg, Sweden; Chong Corp; Alexza Pharmaceuticals of MountainView, Calif.; BLEC, LLC of Charlotte, N.C.; Gaitrend Sarl ofRohrbach-les-Bitche, France; FeelLife Bioscience International ofShenzhen, China; Vishay Electronic BMGH of Selb, Germany; Shenzhen SmacoTechnology Ltd. of Shenzhen, China; Vapor Systems International of BocaRaton, Fla.; Exonoid Medical Devices of Israel; Shenzhen NowotechElectronic of Shenzhen, China; Minilogic Device Corporation of HongKong, China; Shenzhen Kontle Electronics of Shenzhen, China, and FumaInternational, LLC of Medina, Ohio, and 21st Century Smoke of Beloit,Wis.

However, embodiments of electronic smoking articles may be difficult tomanufacture. In this regard, for example, the various components inelectronic smoking articles may be relatively small and/or fragile.Thus, advances with respect to manufacturing electronic smoking articleswould be desirable.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure relates to assembly of aerosol delivery devicesconfigured to produce aerosol. In one aspect a method for assembling acartridge for an aerosol delivery device is provided. The method mayinclude providing a reservoir substrate extending at least partiallyabout an atomizer, providing an outer body configured to at leastpartially receive the reservoir substrate and the atomizer therein, andinserting the reservoir substrate through a tool into the outer body,the tool defining a funnel portion configured to reduce an outerdimension of the reservoir substrate such that the outer dimension ofthe reservoir substrate is less than or equal to an internal dimensionof the outer body to facilitate insertion of the reservoir substrateinto the outer body.

In some embodiments the method may further comprise twisting the toolrelative to the reservoir substrate while inserting the reservoirsubstrate through the tool into the outer body. Providing the reservoirsubstrate extending at least partially about the atomizer may comprisewrapping the reservoir substrate at least partially about the atomizerprior to inserting the reservoir substrate through the tool into theouter body. Wrapping the reservoir substrate at least partially aboutthe atomizer may comprise directing a flow of air at the reservoirsubstrate.

In some embodiments the method may further comprise engaging thereservoir substrate with one or more fingers such that the reservoirsubstrate remains at least partially wrapped about the atomizer whenbeginning to insert the reservoir substrate through the tool into theouter body. The method may further comprise releasing the one or morefingers from the reservoir substrate when the reservoir substrate isinserted to a predetermined depth in the tool. Releasing the one or morefingers may comprise deflecting the one or more fingers away from thereservoir substrate by contacting the one or more fingers with the tool.Releasing the one or more fingers may comprise sequentially releasingthe fingers. The method may further comprise coupling the atomizer to abase prior to wrapping the reservoir substrate at least partially aboutthe atomizer, and coupling the outer body to the base after insertingthe reservoir substrate through the tool into the outer body.Additionally, the method may include supplying the reservoir substratefrom a substantially continuous reservoir substrate input andcontrolling a tension in the substantially continuous reservoirsubstrate input.

In an additional aspect a method for assembling an atomizer for anaerosol delivery device is provided. The method may comprise providing afirst heating terminal, a second heating terminal, and a heatingelement, determining a position of the first heating terminal and thesecond heating terminal, determining a position of the heating element,and affixing the heating element to the first heating terminal and thesecond heating terminal based on the position of the first heatingterminal and the second heating terminal and the position of the heatingelement.

In some embodiments determining the position of the first heatingterminal and the second heating terminal may comprise determining amidpoint between a first heating terminal tab and a second heatingterminal tab. The heating element may comprise a first contact portionand a second contact portion, and determining the position of theheating element may comprise determining a midpoint between the firstcontact portion and the second contact portion. The method may furthercomprise aligning the midpoint between the first heating terminal taband the second heating terminal tab with the midpoint between the firstcontact portion and the second contact portion, engaging the firstcontact portion with the first heating terminal tab, and engaging thesecond contact portion with the second heating terminal tab.

In some embodiments the method may further comprise clamping the firstheating terminal and the second heating terminal such that the firstheating terminal tab and the second heating terminal tab aresubstantially coplanar. Clamping the first heating terminal and thesecond heating terminal may comprise adjusting a spacing between thefirst heating terminal and the second heating terminal. Affixing theheating element to the first heating terminal and the second heatingterminal may comprise directing a laser beam at the first heatingterminal tab and at the second heating terminal tab. Directing the laserbeam at the first heating terminal tab and at the second heatingterminal tab may comprise directing the laser beam at a backside of thefirst heating terminal tab and the second heating terminal tab oppositefrom the heating element.

The method may further comprise inserting the heating element, the firstheating terminal, and the second heating terminal into a substantiallysealed chamber before directing the laser beam at the first heatingterminal tab and at the second heating terminal tab. Providing theheating element may comprise supplying the heating element from asubstantially continuous heating element input and controlling a tensionin the substantially continuous heating element input. The method mayfurther comprise coupling the heating element to a liquid transportelement. Providing the first heating terminal and the second heatingterminal may comprise supplying the first heating terminal from asubstantially continuous first heating terminal input and supplying thesecond heating terminal from a substantially continuous second heatingterminal input. The heating element may comprise a wire wound about aliquid transport element. The wire may comprise two contact portions, acenter portion, and two outer portions positioned outside of the contactportions, the two contact portions and the center portion of the wiredefining the heating element, wherein the contact portions define afirst coil spacing, the center portion defines a second coil spacing,and the outer portions define a third coil spacing, the third coilspacing being greater than the second coil spacing and the second coilspacing being greater than the first coil spacing, and affixing theheating element to the first heating terminal and the second heatingterminal may comprise affixing the contact portions to the first heatingterminal and the second heating terminal.

In an additional aspect, a test fixture is provided. The test fixturemay comprise a receptacle configured to engage a base of a cartridge,first and second electrical contacts coupled to the receptacle andconfigured to engage first and second heating terminals of an atomizerof the cartridge, and a controller configured to communicate with thecartridge through the electrical contacts when the base of the cartridgeis engaged with the receptacle to test the cartridge. The controller maybe configured to determine a resistance of the atomizer of the cartridgeand compare the resistance to a desired resistance.

In some embodiments the controller may be further configured todetermine if the atomizer is shorted to an outer body of the cartridge.The test fixture may further comprise a third electrical contact coupledto the receptacle and configured to engage a control component terminalof the cartridge. The controller may be configured to transmit programcode instructions to an electronic control component of the cartridgethrough the third electrical contact and the control component terminal.The controller may be further configured to read program codeinstructions stored on the electronic control component and determinewhether the program code instructions stored on the electronic controlcomponent correspond to desired program code instructions. The testfixture may further comprise a slot positioned on opposing sides of thereceptacle, the slot being configured to receive a gripper such that thegripper may grasp beneath the base to remove the cartridge from thereceptacle. The test fixture may further comprise an aperture configuredto provide for a flow of air through the base of the cartridge.

In an additional aspect a cartridge filling method is provided. Themethod may include providing a cartridge for an aerosol delivery devicecomprising a reservoir substrate positioned in an outer body,sequentially positioning an outlet of a filling device in proximity to aplurality of angular portions of the reservoir substrate, and directinga flow of an aerosol precursor composition through the outlet of thefilling device at each of the angular portions of the reservoirsubstrate.

In some embodiments the outlet of the filling device may remain out ofcontact with the reservoir substrate. The method may further comprisetransporting the cartridge between a plurality of filling stations,wherein the flow of the aerosol precursor composition is directed to atleast one of the angular portions of the reservoir substrate at each ofthe filling stations. The flow of the aerosol precursor composition maybe directed at each of the angular portions of the reservoir substrateat a first one of the filling stations. The flow of the aerosolprecursor composition may be respectively directed to one of the angularportions of the reservoir substrate at a remainder of the filingstations. The method may further comprise controlling an ambientenvironment in which the cartridge is filled such that the ambientenvironment defines a relative humidity of less than about 40%.

In an additional aspect a method for assembling a cartridge for anaerosol delivery device is provided. The method may comprise grasping abase, providing a plurality of components configured to engage the base,the components being provided in a stationary position, and coupling thecomponents to the base by directing the base into contact with thecomponents in the stationary position.

In some embodiments grasping the base may comprise grasping an internalsurface of an attachment end of the base configured to engage a controlbody. Directing the base into contact with the components in thestationary position may comprise directing the base downwardly intocontact with the components. The method may further comprise insertingthe base into a fixture, and inspecting a position of first and secondheating terminals coupled to the base through the fixture.

In an additional aspect, a transport system configured to transport acartridge for a smoking article during assembly thereof is provided. Thetransport system may comprise a rail, a carriage configured to engagethe rail and move therealong, the carriage comprising a clampingmechanism configured to engage one or more components of a cartridgeduring assembly thereof, and a locking apparatus configured totemporarily restrain movement of the carriage along the rail.

In some embodiments the clamping mechanism may be configured to engage abase of the cartridge. The locking apparatus may comprise a locatormechanism coupled to the carriage and an engagement mechanism configuredto engage the locator mechanism. The locator mechanism may comprise aplurality of pegs. The engagement mechanism may comprise a roller.

These and other features, aspects, and advantages of the disclosure willbe apparent from a reading of the following detailed descriptiontogether with the accompanying drawings, which are briefly describedbelow. The invention includes any combination of two, three, four, ormore of the above-noted embodiments as well as combinations of any two,three, four, or more features or elements set forth in this disclosure,regardless of whether such features or elements are expressly combinedin a specific embodiment description herein. This disclosure is intendedto be read holistically such that any separable features or elements ofthe disclosed invention, in any of its various aspects and embodiments,should be viewed as intended to be combinable unless the context clearlydictates otherwise.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 illustrates an aerosol delivery device comprising a cartridge anda control body, the cartridge being illustrated in an explodedconfiguration and the control body being illustrated in an assembledconfiguration according to an example embodiment of the presentdisclosure;

FIG. 2 illustrates the control body of FIG. 1 in an explodedconfiguration according to an example embodiment of the presentdisclosure;

FIG. 3 schematically illustrates a system for producing cartridges foran aerosol delivery device including a cartridge assembly subsystem, acartridge filling subsystem, a cartridge capping subsystem, a cartridgelabeling subsystem, and an inspection subsystem according to an exampleembodiment of the present disclosure;

FIG. 4 schematically illustrates a first embodiment of the cartridgeassembly subsystem of FIG. 3 according to an example embodiment of thepresent disclosure;

FIG. 5 illustrates a perspective view of a carriage of the cartridgeassembly subsystem of FIG. 4 according to an example embodiment of thepresent disclosure;

FIG. 6 illustrates the carriage of FIG. 5 with a base held thereinaccording to an example embodiment of the present disclosure;

FIG. 7 illustrates a side view of the carriage of FIG. 5 with anengagement mechanism disengaged therefrom according to an exampleembodiment of the present disclosure;

FIG. 8 illustrates a rear view of the carriage of FIG. 5 with theengagement mechanism engaged therewith according to an exampleembodiment of the present disclosure;

FIG. 9 illustrates a perspective view of a substantially continuousterminal input comprising a plurality of terminals according to anexample embodiment of the present disclosure;

FIG. 10 illustrates a perspective view of the terminal sealingsubstation of the cartridge assembly subsystem of FIG. 4 according to anexample embodiment of the present disclosure;

FIG. 11 illustrates an enlarged perspective view of sealant dispensersof the terminal sealing substation of FIG. 10 according to an exampleembodiment of the present disclosure;

FIG. 12 illustrates a perspective view of a heating element couplingsubstation of the cartridge assembly subsystem of FIG. 4 according to anexample embodiment of the present disclosure;

FIG. 13 illustrates a perspective view of a substantially continuousheating element input of the cartridge assembly subsystem of FIG. 4according to an example embodiment of the present disclosure;

FIG. 14 illustrates a perspective view of a preparing portion of theheating element coupling substation of FIG. 12 according to an exampleembodiment of the present disclosure;

FIG. 15 schematically illustrates the preparing portion of the heatingelement coupling substation of FIG. 14 according to an exampleembodiment of the present disclosure;

FIG. 16 illustrates an alternate perspective view of the preparingportion of the heating element coupling substation of FIG. 12 accordingto an example embodiment of the present disclosure;

FIG. 17 illustrates a perspective view of a welding portion of theheating element coupling substation of FIG. 12 according to an exampleembodiment of the present disclosure;

FIG. 18 illustrates an enlarged perspective view of the welding portionof the heating element coupling substation of FIG. 17 according to anexample embodiment of the present disclosure;

FIG. 19 schematically illustrates a terminal fixation mechanism of thewelding portion of the heating element coupling substation of FIG. 17 inan open configuration according to an example embodiment of the presentdisclosure;

FIG. 20 schematically illustrates the terminal fixation mechanism ofFIG. 19 in an intermediate configuration according to an exampleembodiment of the present disclosure;

FIG. 21 schematically illustrates the terminal fixation mechanism ofFIG. 19 in a closed configuration according to an example embodiment ofthe present disclosure;

FIG. 22 schematically illustrates an alternate embodiment of theterminal fixation mechanism of FIG. 19 in an open configurationaccording to an example embodiment of the present disclosure;

FIG. 23 schematically illustrates alignment of a heating element withheating terminals according to an example embodiment of the presentdisclosure;

FIG. 24 schematically illustrates welding the heating element to theheating terminals of FIG. 23 according to an example embodiment of thepresent disclosure;

FIG. 25 illustrates a perspective view of a liquid transport elementheld in a bent configuration according to an example embodiment of thepresent disclosure;

FIG. 26 illustrates a perspective view of a reservoir couplingsubstation of the cartridge assembly subsystem of FIG. 4 according to anexample embodiment of the present disclosure;

FIG. 27 illustrates a perspective view of a moveable clamp of thereservoir coupling substation of FIG. 26 at an upper limit duringdispensing of a substantially continuous reservoir substrate inputaccording to an example embodiment of the present disclosure;

FIG. 28 illustrates a perspective view of the moveable clamp of FIG. 27at a lower limit during dispensing of the substantially continuousreservoir substrate input according to an example embodiment of thepresent disclosure;

FIG. 29 illustrates a perspective view of a transfer mechanism of thereservoir coupling substation of FIG. 26 during receipt of a reservoirsubstrate according to an example embodiment of the present disclosure;

FIG. 30 illustrates a perspective view of the transfer mechanism of FIG.29 proximate fingers of the reservoir coupling substation of FIG. 26according to an example embodiment of the present disclosure;

FIG. 31 illustrates a perspective view of movement of the fingers of thereservoir coupling subsystem of FIG. 26 toward the transfer mechanism ofFIG. 29 according to an example embodiment of the present disclosure;

FIG. 32 illustrates clamping of the fingers of the reservoir couplingsubstation of FIG. 26 according to an example embodiment of the presentdisclosure;

FIG. 33 schematically illustrates wrapping a reservoir substrate about aheating element using the reservoir coupling substation of FIG. 26according to an example embodiment of the present disclosure;

FIG. 34 illustrates an outer body supply mechanism of an outer bodycoupling substation of the cartridge assembly subsystem of FIG. 4according to an example embodiment of the present disclosure;

FIG. 35 illustrates a section of a tool configured to direct an outerbody over the reservoir substrate of the outer body coupling substationof FIG. 34 according to an example embodiment of the present disclosure;

FIG. 36 illustrates directing an outer body over a reservoir substrateusing the fingers of the reservoir coupling subsystem of FIG. 26according to an example embodiment of the present disclosure;

FIG. 36A illustrates directing an outer body over a reservoir substrateusing multiple pairs of fingers according to an alternate exampleembodiment of the present disclosure;

FIG. 37 illustrates a perspective view of a crimper of the outer bodycoupling substation of FIG. 34 according to an example embodiment of thepresent disclosure;

FIG. 38 illustrates a side view of a section of the crimper of FIG. 37according to an example embodiment of the present disclosure;

FIG. 39 illustrates an enlarged partial perspective view of a section ofthe crimper of FIG. 37 according to an example embodiment of the presentdisclosure;

FIG. 40 schematically illustrates a second embodiment of the cartridgeassembly subsystem of FIG. 3 according to an example embodiment of thepresent disclosure;

FIG. 41 illustrates an overhead view of the cartridge assembly subsystemof FIG. 40 according to an example embodiment of the present disclosure;

FIG. 42 illustrates a perspective view of a terminal coupling substationof the cartridge assembly subsystem of FIG. 40 according to an exampleembodiment of the present disclosure;

FIG. 43 illustrates a perspective view of a base gripper of the terminalcoupling substation of FIG. 42 according to an example embodiment of thepresent disclosure;

FIG. 44 illustrates a perspective view of a die of the terminal couplingsubstation of FIG. 42 according to an example embodiment of the presentdisclosure;

FIG. 44A illustrates an enlarged perspective view of the die of FIG. 44;

FIG. 45 illustrates a transfer member of the terminal couplingsubstation of FIG. 42 according to an example embodiment of the presentdisclosure;

FIG. 46 illustrates a perspective view of a control component couplingsubstation of the cartridge assembly subsystem of FIG. 40 according toan example embodiment of the present disclosure;

FIG. 47 illustrates an enlarged perspective view of the controlcomponent coupling substation of FIG. 46 according to an exampleembodiment of the present disclosure;

FIG. 48 illustrates a perspective view of a flow tube couplingsubstation of the cartridge assembly subsystem of FIG. 40 according toan example embodiment of the present disclosure;

FIG. 49 illustrates a side view of a terminal gripper of the cartridgeassembly subsystem of FIG. 40 according to an example embodiment of thepresent disclosure;

FIG. 50 illustrates a perspective view of the terminal gripper of FIG.49 gripping heating terminals according to an example embodiment of thepresent disclosure;

FIG. 51 illustrates an enlarged side view of the terminal gripper ofFIG. 49 gripping heating terminals according to an example embodiment ofthe present disclosure;

FIG. 52 illustrates a perspective view of a heating element couplingsubstation of the cartridge assembly subsystem of FIG. 40 according toan example embodiment of the present disclosure;

FIG. 53 illustrates a spool of a substantially continuous heatingelement input of the heating element coupling substation of FIG. 52according to an example embodiment of the present disclosure;

FIG. 54 illustrates a perspective view of a welding portion of theheating element coupling substation of FIG. 52 according to an exampleembodiment of the present disclosure;

FIG. 55 illustrates a side view of the welding portion of the heatingelement coupling substation of FIG. 52 during welding according to anexample embodiment of the present disclosure;

FIG. 56 illustrates a liquid transport element bending substation of thecartridge assembly subsystem of FIG. 40 according to an exampleembodiment of the present disclosure;

FIG. 57 illustrates the liquid transport element bending substation ofFIG. 56 with a partially assembled cartridge received therein accordingto an example embodiment of the present disclosure;

FIG. 58 illustrates a perspective view of a base and wick gripper of thecartridge assembly subsystem of FIG. 40 according to an exampleembodiment of the present disclosure;

FIG. 59 illustrates a side view of the base and wick gripper of FIG. 58gripping a partially assembled cartridge according to an exampleembodiment of the present disclosure;

FIG. 60 illustrates a spool of a substantially continuous reservoirsubstrate input of a reservoir coupling substation of the cartridgeassembly subsystem of FIG. 40 according to an example embodiment of thepresent disclosure;

FIG. 61 illustrates a perspective view of a singulation unit of thereservoir coupling substation of FIG. 60 according to an exampleembodiment of the present disclosure;

FIG. 62 illustrates an alternate perspective view of the singulationunit of the reservoir coupling substation of FIG. 61 according to anexample embodiment of the present disclosure;

FIG. 63 illustrates a perspective view of a wrapping mechanism of thereservoir coupling substation of the cartridge assembly subsystem ofFIG. 40 according to an example embodiment of the present disclosure;

FIG. 64 illustrates an overhead view of the outer body couplingsubstation of the cartridge assembly subsystem of FIG. 40 according toan example embodiment of the present disclosure;

FIG. 65 illustrates an enlarged overhead view of the outer body couplingsubstation of FIG. 64 with a tool configured to receive the partiallyassembled cartridge therethrough in an open configuration according toan example embodiment of the present disclosure;

FIG. 66 illustrates an enlarged overhead view of the outer body couplingsubstation of FIG. 64 with the tool configured to receive the partiallyassembled cartridge therethrough in a closed configuration according toan example embodiment of the present disclosure;

FIG. 67 illustrates an exploded view of a reservoir gripper of the outerbody coupling substation of FIG. 64 according to an example embodimentof the present disclosure;

FIG. 68 illustrates the reservoir gripper of FIG. 67 in an assembledconfiguration according to an example embodiment of the presentdisclosure;

FIG. 69 illustrates an alternate embodiment of a reservoir gripper ofthe outer body coupling substation of FIG. 64 including a fingeraccording to an example embodiment of the present disclosure;

FIG. 70 illustrates an enlarged perspective view of a heating elementformed by directing a wire through a liquid transport element andwrapping the wire thereabout according to an example embodiment of thepresent disclosure;

FIG. 71 schematically illustrates the cartridge filling subsystem ofFIG. 3 according to an example embodiment of the present disclosure;

FIG. 72 illustrates an overhead view of a partially assembled cartridgeduring filling and prior to coupling of a mouthpiece thereto accordingto an example embodiment of the present disclosure;

FIG. 73 illustrates a cartridge during filling according to an exampleembodiment of the present disclosure;

FIG. 74 illustrates a side view camera of the inspection subsystem ofFIG. 3 configured to inspect a distance to which terminals extend from abase according to an example embodiment of the present disclosure;

FIG. 75 illustrates an end view camera of the inspection subsystem ofFIG. 3 configured to inspect a radial position of terminals according toan example embodiment of the present disclosure;

FIG. 76 illustrates side and end view cameras of the inspectionsubsystem of FIG. 3 configured to inspect terminal height and radialposition according to an alternate embodiment of the present disclosure;

FIG. 77 illustrates a side view of a fixture of the inspection subsystemof FIG. 3 configured to facilitate inspection of terminals according toan embodiment of the present disclosure;

FIG. 78 illustrates side and end view cameras of the inspectionsubsystem of FIG. 3 configured to inspect an outer body of a cartridgeaccording to an example embodiment of the present disclosure;

FIG. 79 illustrates side and end view cameras of the inspectionsubsystem of FIG. 3 configured to inspect an outer body of a cartridgeaccording to an alternate example embodiment of the present disclosure;

FIG. 80 illustrates a perspective view of a blow-through station of theinspection subsystem of FIG. 3 according to an example embodiment of thepresent disclosure;

FIG. 81 illustrates a perspective view of a blow-through station of theinspection subsystem of FIG. 3 according to an alternate exampleembodiment of the present disclosure;

FIG. 82 illustrates perspective view of a pressure drop station of theinspection subsystem of FIG. 3 according to an example embodiment of thepresent disclosure;

FIG. 83 illustrates a perspective view of a pressure drop station of theinspection subsystem of FIG. 3 according to an alternate exampleembodiment of the present disclosure;

FIG. 84 illustrates a perspective view of an electrical test station ofthe inspection subsystem of FIG. 3 including a test fixture according toan example embodiment of the present disclosure;

FIG. 85 illustrates an enlarged perspective view of the test fixture ofFIG. 84 according to an example embodiment of the present disclosure;

FIG. 86 illustrates a sectional view through the test fixture of FIG. 84according to an example embodiment of the present disclosure;

FIG. 87 illustrates a perspective view of an electrical test station ofthe inspection subsystem of FIG. 3 including a test fixture according toan alternate example embodiment of the present disclosure;

FIG. 88 schematically illustrates a method for assembling a cartridgefor an aerosol delivery device according to an example embodiment of thepresent disclosure FIG. 89 schematically illustrates a method forassembling an atomizer for an aerosol delivery device according to anexample embodiment of the present disclosure;

FIG. 90 schematically illustrates a cartridge filling method accordingto an example embodiment of the present disclosure;

FIG. 91 schematically illustrates a method for assembling a cartridgefor an aerosol delivery device according to an example embodiment of thepresent disclosure; and

FIG. 92 schematically illustrates a controller according to an exampleembodiment of the present disclosure.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present disclosure will now be described more fully hereinafter withreference to exemplary embodiments thereof. These exemplary embodimentsare described so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Indeed, the disclosure may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As used in the specification, andin the appended claims, the singular forms “a”, “an”, “the”, includeplural variations unless the context clearly dictates otherwise.

As described hereinafter, embodiments of the present disclosure relateto aerosol delivery devices and methods and equipment for assemblythereof. Aerosol delivery devices according to the present disclosuremay use electrical energy to heat a material (preferably withoutcombusting the material to any significant degree) to form an inhalablesubstance; such articles most preferably being sufficiently compact tobe considered “hand-held” devices. An aerosol delivery device mayprovide some or all of the sensations (e.g., inhalation and exhalationrituals, types of tastes or flavors, organoleptic effects, physicalfeel, use rituals, visual cues such as those provided by visibleaerosol, and the like) of smoking a cigarette, cigar, or pipe, withoutany substantial degree of combustion of any component of that article ordevice. The aerosol delivery device may not produce smoke in the senseof the aerosol resulting from by-products of combustion or pyrolysis oftobacco, but rather, that the article or device may yield vapors(including vapors within aerosols that can be considered to be visibleaerosols that might be considered to be described as smoke-like)resulting from volatilization or vaporization of certain components ofthe article or device. In highly preferred embodiments, aerosol deliverydevices may incorporate tobacco and/or components derived from tobacco.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices can be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances can be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like.

In use, aerosol delivery devices of the present disclosure may besubjected to many of the physical actions employed by an individual inusing a traditional type of smoking article (e.g., a cigarette, cigar orpipe that is employed by lighting and inhaling tobacco). For example,the user of an aerosol delivery device of the present disclosure canhold that article much like a traditional type of smoking article, drawon one end of that article for inhalation of aerosol produced by thatarticle, take puffs at selected intervals of time, etc.

Aerosol delivery devices of the present disclosure generally include anumber of components provided within an outer body or shell. The overalldesign of the outer body or shell can vary, and the format orconfiguration of the outer body that can define the overall size andshape of the aerosol delivery device can vary. Typically, an elongatedbody resembling the shape of a cigarette or cigar can be a formed from asingle, unitary shell; or the elongated body can be formed of two ormore separable pieces. For example, an aerosol delivery device cancomprise an elongated shell or body that can be substantially tubular inshape and, as such, resemble the shape of a conventional cigarette orcigar. In one embodiment, all of the components of the aerosol deliverydevice are contained within one outer body or shell. Alternatively, anaerosol delivery device can comprise two or more shells that are joinedand are separable. For example, an aerosol delivery device can possessat one end a control body comprising an outer body or shell containingone or more reusable components (e.g., a rechargeable battery andvarious electronics for controlling the operation of that article), andat the other end and removably attached thereto an outer body or shellcontaining a disposable portion (e.g., a disposable flavor-containingcartridge). More specific formats, configurations and arrangements ofcomponents within the single shell type of unit or within a multi-pieceseparable shell type of unit will be evident in light of the furtherdisclosure provided herein. Additionally, various aerosol deliverydevice designs and component arrangements can be appreciated uponconsideration of the commercially available electronic aerosol deliverydevices, such as those representative products listed above in thepresent disclosure. For example, an embodiment of an aerosol deliverydevice comprising multiple outer bodies and a coupler is described inU.S. patent application Ser. No. 14/170,838, filed Feb. 3, 2014, toBless et al., which is incorporated herein by reference in its entirety,as noted above.

Aerosol delivery devices of the present disclosure most preferablycomprise some combination of a power source (i.e., an electrical powersource), at least one control component (e.g., means for actuating,controlling, regulating and ceasing power for heat generation, such asby controlling electrical current flow from the power source to othercomponents of the article), a heater or heat generation component (e.g.,an electrical resistance heating element or component commonly referredto as an “atomizer”), and an aerosol precursor composition (e.g.,commonly a liquid capable of yielding an aerosol upon application ofsufficient heat, such as ingredients commonly referred to as “smokejuice,” “e-liquid” and “e-juice”), and a mouthend region or tip forallowing draw upon the aerosol delivery device for aerosol inhalation(e.g., a defined air flow path through the article such that aerosolgenerated can be withdrawn therefrom upon draw).

Alignment of the components within the aerosol delivery device can vary.In specific embodiments, the aerosol precursor composition can belocated near an end of the article (e.g., within a cartridge, which incertain circumstances can be replaceable and disposable), which may beconfigured to be positioned proximal to the mouth of a user so as tomaximize aerosol delivery to the user. Other configurations, however,are not excluded. Generally, the heating element can be positionedsufficiently near the aerosol precursor composition so that heat fromthe heating element can volatilize the aerosol precursor (as well as oneor more flavorants, medicaments, or the like that may likewise beprovided for delivery to a user) and form an aerosol for delivery to theuser. When the heating element heats the aerosol precursor composition,an aerosol is formed, released, or generated in a physical form suitablefor inhalation by a consumer. It should be noted that the foregoingterms are meant to be interchangeable such that reference to release,releasing, releases, or released includes form or generate, forming orgenerating, forms or generates, and formed or generated. Specifically,an inhalable substance is released in the form of a vapor or aerosol ormixture thereof. Additionally, the selection of various aerosol deliverydevice components can be appreciated upon consideration of thecommercially available electronic aerosol delivery devices, such asthose representative products listed above in the present disclosure.

An aerosol delivery device incorporates a battery or other electricalpower source to provide current flow sufficient to provide variousfunctionalities to the article, such as powering of a heater, poweringof control systems, powering of indicators, and the like. The powersource can take on various embodiments. Preferably, the power source isable to deliver sufficient power to rapidly heat the heating element toprovide for aerosol formation and power the article through use for thedesired duration of time. The power source preferably is sized to fitconveniently within the aerosol delivery device so that the aerosoldelivery device can be easily handled; and additionally, a preferredpower source is of a sufficiently light weight to not detract from adesirable smoking experience.

One example embodiment of an aerosol delivery device 100 is illustratedin FIG. 1. In particular, FIG. 1 illustrates a partially exploded viewof an aerosol delivery device 100 including a cartridge 200 and acontrol body 300. The cartridge 200 and the control body 300 can bepermanently or detachably aligned in a functioning relationship. Variousmechanisms may connect the cartridge 200 to the control body 300 toresult in a threaded engagement, a press-fit engagement, an interferencefit, a magnetic engagement, or the like. The aerosol delivery device 100may be substantially rod-like, substantially tubular shaped, orsubstantially cylindrically shaped in some embodiments when thecartridge 200 and the control body 300 are in an assembledconfiguration.

In specific embodiments, one or both of the cartridge 200 and thecontrol body 300 may be referred to as being disposable or as beingreusable. For example, the control body 300 may have a replaceablebattery or a rechargeable battery and thus may be combined with any typeof recharging technology, including connection to a typical alternatingcurrent electrical outlet, connection to a car charger (i.e., cigarettelighter receptacle), and connection to a computer, such as through auniversal serial bus (USB) cable. Further, in some embodiments thecartridge 200 may comprise a single-use cartridge, as disclosed in U.S.patent application Ser. No. 13/603,612, filed Sep. 5, 2012, which isincorporated herein by reference in its entirety.

FIG. 2 illustrates an exploded view of the control body 300 of theaerosol delivery device 100 according to an example embodiment of thepresent disclosure. As illustrated, the control body 300 may comprise acoupler 302, an outer body 304, a sealing member 306, an adhesive member308 (e.g., KAPTON® tape), a flow sensor 310 (e.g., a puff sensor orpressure switch), a control component 312, a spacer 314, an electricalpower source 316 (e.g., a battery, which may be rechargeable), a circuitboard with an indicator 318 (e.g., a light emitting diode (LED)), aconnector circuit 320, and an end cap 322. Examples of electrical powersources are described in U.S. Pat. App. Pub. No. 2010/0028766 byPeckerar et al., the disclosure of which is incorporated herein byreference in its entirety.

With respect to the flow sensor 310, representative current regulatingcomponents and other current controlling components including variousmicrocontrollers, sensors, and switches for aerosol delivery devices aredescribed in U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. Nos.4,922,901, 4,947,874, and 4,947,875, all to Brooks et al., U.S. Pat. No.5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhaueret al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No.8,205,622 to Pan, all of which are incorporated herein by reference intheir entireties. Reference also is made to the control schemesdescribed in U.S. application Ser. No. 13/837,542 to Ampolini et al.,filed Mar. 15, 2013, which is incorporated herein by reference in itsentirety.

In one embodiment the indicator 318 may comprise one or more lightemitting diodes. The indicator 318 can be in communication with thecontrol component 312 through the connector circuit 320 and illuminate,for example, during a user drawing on a cartridge coupled to the coupler302, as detected by the flow sensor 310. The end cap 322 may be adaptedto make visible the illumination provided thereunder by the indicator318. Accordingly, the indicator 318 may illuminate during use of theaerosol delivery device 100 to simulate the lit end of a smokingarticle. However, in other embodiments the indicator 318 can be providedin varying numbers and can take on different shapes and can even be anopening in the outer body (such as for release of sound when suchindicators are present).

Still further components can be utilized in the aerosol delivery deviceof the present disclosure. For example, U.S. Pat. No. 5,154,192 toSprinkel et al. discloses indicators for smoking articles; U.S. Pat. No.5,261,424 to Sprinkel, Jr. discloses piezoelectric sensors that can beassociated with the mouth-end of a device to detect user lip activityassociated with taking a draw and then trigger heating; U.S. Pat. No.5,372,148 to McCafferty et al. discloses a puff sensor for controllingenergy flow into a heating load array in response to pressure dropthrough a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. disclosesreceptacles in a smoking device that include an identifier that detectsa non-uniformity in infrared transmissivity of an inserted component anda controller that executes a detection routine as the component isinserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer etal. describes a defined executable power cycle with multipledifferential phases; U.S. Pat. No. 5,934,289 to Watkins et al. disclosesphotonic-optronic components; U.S. Pat. No. 5,954,979 to Counts et al.discloses means for altering draw resistance through a smoking device;U.S. Pat. No. 6,803,545 to Blake et al. discloses specific batteryconfigurations for use in smoking devices; U.S. Pat. No. 7,293,565 toGriffen et al. discloses various charging systems for use with smokingdevices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses computerinterfacing means for smoking devices to facilitate charging and allowcomputer control of the device; U.S. Pat. App. Pub. No. 2010/0163063 byFernando et al. discloses identification systems for smoking devices;and WO 2010/003480 by Flick discloses a fluid flow sensing systemindicative of a puff in an aerosol generating system; all of theforegoing disclosures being incorporated herein by reference in theirentireties. Further examples of components related to electronic aerosoldelivery articles and disclosing materials or components that may beused in the present article include U.S. Pat. No. 4,735,217 to Gerth etal.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,666,977to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat.No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No.6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S.Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S.Pat. No. 7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan; U.S.Pat. Nos. 8,156,944 and 8,375,957 to Hon; U.S. Pat. App. Pub. Nos.2006/0196518 and 2009/0188490 to Hon; U.S. Pat. App. Pub. No.2009/0272379 to Thorens et al.; U.S. Pat. App. Pub. Nos. 2009/0260641and 2009/0260642 to Monsees et al.; U.S. Pat. App. Pub. Nos.2008/0149118 and 2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub. No.2010/0307518 to Wang; WO 2010/091593 to Hon; WO 2013/089551 to Foo; andU.S. patent application Ser. No. 13/841,233, filed Mar. 15, 2013, eachof which is incorporated herein by reference in its entirety. A varietyof the materials disclosed by the foregoing documents may beincorporated into the present devices in various embodiments, and all ofthe foregoing disclosures are incorporated herein by reference in theirentireties.

Returning to FIG. 1, the cartridge 200 is illustrated in an explodedconfiguration. As illustrated, the cartridge 200 may comprise a baseshipping plug 202, a base 204, a control component terminal 206, anelectronic control component 208, a flow tube 210, an atomizer 212, areservoir substrate 214, an outer body 216, a label 218, a mouthpiece220, and a mouthpiece shipping plug 222 according to an exampleembodiment of the present disclosure. The base 204 may be coupled to afirst end of the outer body 216 and the mouthpiece 220 may be coupled toan opposing second end of the outer body to enclose the remainingcomponents of the cartridge 200 therein. The base 204 may be configuredto engage the coupler 302 of the control body 300. In some embodimentsthe base 204 may comprise anti-rotation features that substantiallyprevent relative rotation between the cartridge and the control body asdisclosed in U.S. patent application Ser. No. 13/840,264, filed Mar. 15,2013, which is incorporated herein by reference in its entirety.

The base shipping plug 202 may be configured to engage and protect thebase 204 prior to use of the cartridge 200. Similarly, the mouthpieceshipping plug 222 may be configured to engage and protect the mouthpiece220 prior to use of the cartridge 200. The control component terminal206, the electronic control component 208, the flow tube 210, theatomizer 212, and the reservoir substrate 214 may be retained within theouter body 216. The label 218 may at least partially surround the outerbody 216 and include information such as a product identifier thereon.

The atomizer 212 may comprise a first heating terminal 234 a and asecond heating terminal 234 b, a liquid transport element 238 and aheating element 240. In this regard, the reservoir substrate 214 may beconfigured to hold an aerosol precursor composition. The aerosolprecursor composition, also referred to as a vapor precursorcomposition, may comprise a variety of components including, by way ofexample, a polyhydric alcohol (e.g., glycerin, propylene glycol, or amixture thereof), nicotine, tobacco, tobacco extract, and/or flavorants.Various components that may be included in the aerosol precursorcomposition are described in U.S. Pat. No. 7,726,320 to Robinson et al.,which is incorporated herein by reference in its entirety. Additionalrepresentative types of aerosol precursor compositions are set forth inU.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al.; U.S. Pat. No.5,101,839 to Jakob et al.; PCT WO 98/57556 to Biggs et al.; and Chemicaland Biological Studies on New Cigarette Prototypes that Heat Instead ofBurn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988); thedisclosures of which are incorporated herein by reference in theirentireties. Other aerosol precursors which may be employed in theaerosol delivery device of the present disclosure include the aerosolprecursors included in the VUSE® product by R. J. Reynolds VaporCompany, the BLU™ product by Lorillard Technologies, the Mistic Mentholproduct by Mistic Ecigs, and the Vype product by CN Creative Ltd. Alsodesirable are the so-called “Smoke Juices” for electronic cigarettesthat have been available from Johnson Creek Enterprises LLC. Additionalexemplary formulations for aerosol precursor materials that may be usedaccording to the present disclosure are described in U.S. Pat. Pub. No.2013/0008457 to Zheng et al., the disclosure of which is incorporatedherein by reference in its entirety.

The reservoir substrate 214 may comprise a plurality of layers ofnonwoven fibers formed into the shape of a tube encircling the interiorof the outer body 216 of the cartridge 200. Thus, liquid components, forexample, can be sorptively retained by the reservoir substrate 214. Thereservoir substrate 214 is in fluid connection with the liquid transportelement 238. Thus, the liquid transport element 238 may be configured totransport liquid from the reservoir substrate 214 to the heating element240 via capillary action.

As illustrated, the liquid transport element 238 may be in directcontact with the heating element 240. As further illustrated in FIG. 1,the heating element 240 may comprise a wire defining a plurality ofcoils wound about the liquid transport element 238. In some embodimentsthe heating element 240 may be formed by winding the wire about theliquid transport element 238 as described in U.S. patent applicationSer. No. 13/708,381, filed Dec. 7, 2012, which is incorporated herein byreference in its entirety. Further, in some embodiments the wire maydefine a variable coil spacing, as described in U.S. patent applicationSer. No. 13/827,994, filed Mar. 14, 2013, which is incorporated hereinby reference in its entirety. Various embodiments of materialsconfigured to produce heat when electrical current is appliedtherethrough may be employed to form the heating element 240. Examplematerials from which the wire coil may be formed include Kanthal(FeCrAl), Nichrome, Molybdenum disilicide (MoSi₂), molybdenum silicide(MoSi), Molybdenum disilicide doped with Aluminum (Mo(Si,Al)₂), graphiteand graphite-based materials; and ceramic (e.g., a positive or negativetemperature coefficient ceramic).

However, various other embodiments of methods may be employed to formthe heating element 240, and various other embodiments of heatingelements may be employed in the atomizer 212. For example, a stampedheating element may be employed in the atomizer, as described in U.S.patent application Ser. No. 13/842,125, filed Mar. 15, 2013, which isincorporated herein by reference in its entirety. Further to the above,additional representative heating elements and materials for use thereinare described in U.S. Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No.5,093,894 to Deevi et al.; U.S. Pat. No. 5,224,498 to Deevi et al.; U.S.Pat. No. 5,228,460 to Sprinkel Jr., et al.; U.S. Pat. No. 5,322,075 toDeevi et al.; U.S. Pat. No. 5,353,813 to Deevi et al.; U.S. Pat. No.5,468,936 to Deevi et al.; U.S. Pat. No. 5,498,850 to Das; U.S. Pat. No.5,659,656 to Das; U.S. Pat. No. 5,498,855 to Deevi et al.; U.S. Pat. No.5,530,225 to Hajaligol; U.S. Pat. No. 5,665,262 to Hajaligol; U.S. Pat.No. 5,573,692 to Das et al.; and U.S. Pat. No. 5,591,368 to Fleischhaueret al., the disclosures of which are incorporated herein by reference intheir entireties. Further, chemical heating may be employed in otherembodiments. Various additional examples of heaters and materialsemployed to form heaters are described in U.S. patent application Ser.No. 13/602,871, filed Sep. 4, 2012, which is incorporated herein byreference, as noted above.

A variety of heater components may be used in the present aerosoldelivery device. In various embodiments, one or more microheaters orlike solid state heaters may be used. Embodiments of microheaters thatmay be utilized are further described herein. Further microheaters andatomizers incorporating microheaters suitable for use in the presentlydisclosed devices are described in U.S. patent application Ser. No.13/602,871, filed Sep. 4, 2012, which is incorporated herein byreference in its entirety.

The first heating terminal 234 a and the second heating terminal 234 b(e.g., positive and negative terminals) at the opposing ends of theheating element 240 are configured to form an electrical connection withthe control body 300 when the cartridge 200 is connected thereto.Further, when the control body 300 is coupled to the cartridge 200, theelectronic control component 208 may form an electrical connection withthe control body through the control component terminal 206. The controlbody 300 may thus employ the electronic control component 208 todetermine whether the cartridge 200 is genuine and/or perform otherfunctions. Further, various examples of electronic control componentsand functions performed thereby are described in U.S. patent applicationSer. No. 13/647,000, filed Oct. 8, 2012, which is incorporated herein byreference in its entirety.

During use, a user may draw on the mouthpiece 220 of the cartridge 200of the aerosol delivery device 100. This may pull air through an openingin the control body 300 or in the cartridge. For example, in oneembodiment an opening may be defined between the coupler 302 and theouter body 304 of the control body 300, as described in U.S. patentapplication Ser. No. 13/841,233; Filed Mar. 15, 2013, which isincorporated herein by reference in its entirety. However, the flow ofair may be received through other parts of the aerosol delivery device100 in other embodiments. As noted above, in some embodiments thecartridge 200 may include the flow tube 210. The flow tube 210 may beconfigured to direct the flow of air received from the control body 300to the heating element 240 of the atomizer 212.

A sensor in the aerosol delivery device 100 (e.g., a puff or flow sensorin the control body 300) may sense the puff. When the puff is sensed,the control body 300 may direct current to the heating element 240through a circuit including the first heating terminal 234 a and thesecond heating terminal 234 b. Accordingly, the heating element 240 mayvaporize the aerosol precursor composition directed to an aerosolizationzone from the reservoir substrate 214 by the liquid transport element238. Thus, the mouthpiece 220 may allow passage of air and entrainedvapor (i.e., the components of the aerosol precursor composition in aninhalable form) from the cartridge 200 to a consumer drawing thereon.

Various other details with respect to the components that may beincluded in the cartridge 200, are provided, for example, in U.S. patentapplication Ser. No. 13/840,264, filed Mar. 15, 2013, which isincorporated herein by reference in its entirety. In this regard, FIG. 7thereof illustrates an enlarged exploded view of a base and a controlcomponent terminal; FIG. 8 thereof illustrates an enlarged perspectiveview of the base and the control component terminal in an assembledconfiguration; FIG. 9 thereof illustrates an enlarged perspective viewof the base, the control component terminal, an electronic controlcomponent, and heating terminals of an atomizer in an assembledconfiguration; FIG. 10 thereof illustrates an enlarged perspective viewof the base, the atomizer, and the control component in an assembledconfiguration; FIG. 11 thereof illustrates an opposing perspective viewof the assembly of FIG. 10 thereof; FIG. 12 thereof illustrates anenlarged perspective view of the base, the atomizer, the flow tube, andthe reservoir substrate in an assembled configuration; FIG. 13 thereofillustrates a perspective view of the base and an outer body in anassembled configuration; FIG. 14 thereof illustrates a perspective viewof a cartridge in an assembled configuration; FIG. 15 thereofillustrates a first partial perspective view of the cartridge of FIG. 14thereof and a coupler for a control body; FIG. 16 thereof illustrates anopposing second partial perspective view of the cartridge of FIG. 14thereof and the coupler of FIG. 11 thereof; FIG. 17 thereof illustratesa perspective view of a cartridge including a base with an anti-rotationmechanism; FIG. 18 thereof illustrates a perspective view of a controlbody including a coupler with an anti-rotation mechanism; FIG. 19thereof illustrates alignment of the cartridge of FIG. 17 with thecontrol body of FIG. 18; FIG. 3 thereof illustrates an aerosol deliverydevice comprising the cartridge of FIG. 17 thereof and the control bodyof FIG. 18 thereof with a modified view through the aerosol deliverydevice illustrating the engagement of the anti-rotation mechanism of thecartridge with the anti-rotation mechanism of the connector body; FIG. 4thereof illustrates a perspective view of a base with an anti-rotationmechanism; FIG. 5 thereof illustrates a perspective view of a couplerwith an anti-rotation mechanism; and FIG. 6 thereof illustrates asectional view through the base of FIG. 4 thereof and the coupler ofFIG. 5 thereof in an engaged configuration.

Various components of an aerosol delivery device according to thepresent disclosure can be chosen from components described in the artand commercially available. Reference is made for example to thereservoir and heater system for controllable delivery of multipleaerosolizable materials in an electronic smoking article disclosed inU.S. Pat. App. Pub. No. 2014/0000638 to Sebastian et al., which isincorporated herein by reference in its entirety.

Note further that portions of the cartridge 200 illustrated in FIG. 1are optional. In this regard, by way of example, the cartridge 200 maynot include the flow tube 210, the control component terminal 206,and/or the electronic control component 208 in some embodiments.

In another embodiment substantially the entirety of the cartridge may beformed from one or more carbon materials, which may provide advantagesin terms of biodegradability and absence of wires. In this regard, theheating element may comprise carbon foam, the reservoir may comprisecarbonized fabric, and graphite may be employed to form an electricalconnection with the battery and controller. An example embodiment of acarbon-based cartridge is provided in U.S. Pat. App. Pub. No.2013/0255702 to Griffith et al., which is incorporated herein byreference in its entirety.

As described above, cartridges of aerosol delivery devices may include anumber of components. Some of the components may be relatively smalland/or relatively delicate. Accordingly, precise manufacturingtechniques may be required to form the aerosol delivery devices. In thisregard, aerosol delivery devices have traditionally been formed viamanual assembly. However, use of manual labor to assemble aerosoldelivery devices suffers from certain detriments. In this regard, thequality of aerosol delivery devices produced via manual labor is only asgood as the workers performing the labor. Further, even skilled workersmay make errors from time-to-time. Additionally, manual labor may berelatively costly. Accordingly, as result of these issues and otherissues associated with the production of aerosol delivery devices viamanual labor, it may be desirable to produce aerosol delivery devices inan automated manner. Accordingly, automated production of cartridges foraerosol delivery devices is discussed hereinafter, which may provideenhanced repeatability, lower costs, and/or avoid other issues notedabove.

In this regard, FIG. 3 schematically illustrates an embodiment of asystem 400 for producing cartridges (e.g., the above-describedcartridges 200) for an aerosol delivery device (e.g., theabove-described aerosol delivery device 100). Note that the abovedescribed aerosol delivery device 100 is provided by way of example. Inthis regard, the methods, systems, and apparatuses described herein maybe employed to form various embodiments of cartridges that differ fromthe above described cartridges in one or more respects.

As illustrated, the system 400 may include various subsystems thatperform particular functions in the formation of the completedcartridges 200. Note that although the subsystems are illustrated asbeing separate from one another, the subsystems may overlap. Forexample, in some embodiments common equipment may perform two or morefunctions (e.g., assembly and filling or capping and labeling, etc.),rather than the particular functions being performed by separateequipment.

Further, the various subsystems and portions thereof are separatelyusable. In this regard, although the subsystems and portions thereof aregenerally described herein as being usable together, this is by way ofexample. Accordingly, any of the subsystems or portions thereofdescribed herein may be usable by themselves or in any combination withsome or all of the other subsystems and portions thereof describedherein. Thus, for example, although an example embodiment of a cartridgefilling subsystem is described hereinafter as being employed to fillcartridges filled by embodiments of cartridge assembly subsystemsdisclosed herein, the cartridge filling subsystem may be employed tofill cartridges formed by other subsystems and/or the cartridgesassembled by the cartridge assembly subsystems may be filled by othercartridge filling subsystems. Further, although particular embodimentsof portions of the subsystems are disclosed hereinafter, theseembodiments are provided for example purposes only. Accordingly, in someembodiments the subsystems may include fewer or additional portions.Thus, each portion of each subsystem, and each portion of the overallsystem is not required in all embodiments.

As illustrated, the subsystems may include a cartridge assemblysubsystem 402 configured to form unfilled cartridges 404 from components406 (e.g., the base 204, the heating terminals 234 a, 234 b, etc.). Acartridge filling subsystem 408 may fill the unfilled cartridges 404 toproduce filled cartridges 410. A cartridge capping subsystem 412 may capthe filled cartridges 410 to produce capped cartridges 414. A cartridgelabeling subsystem 416 may apply labels to the capped cartridges 414 tocomplete the completed cartridges 200.

The system 400 may additionally include an inspection subsystem 418. Theinspection subsystem 418 may inspect the components 406, the unfilledcartridges 404, the filled cartridges 410, the capped cartridges 414,and/or the completed cartridges 200. Further, in some embodiments thecartridges may be inspected at intermediate states of completion at oneor more of the cartridge assembly subsystem 402, the cartridge fillingsubsystem 408, the cartridge capping subsystem 412, and the cartridgelabeling subsystem 416. Accordingly, the cartridges 200 and componentsthereof may be inspected before, during, and after completion thereof.

The system my further at least one controller 417. The controller 417may be configured to control the cartridge assembly subsystem 402, thecartridge filling subsystem 408, the cartridge capping subsystem 412,and/or the cartridge labeling subsystem 416. In this regard, thecontroller may be configured to receive data from one or more of thesensors described herein and output instructions based thereon, inaddition to otherwise directing the operations described herein.

Note that some or all of the system 400 may be automated. In thisregard, as described hereinafter, robotic apparatuses may be employed insome embodiments of the system 400. The robotic apparatuses may beprovided from various robotic manufacturers including, by way ofexample, DENSO Robotics of Long Beach, Calif., FANUC of Rochester Hills,Mich., Mitsubishi Electric Automation of Vernon Hills, Ill., and SiemensAutomation Technology of Munich, Germany.

An example embodiment of the cartridge assembly subsystem 402 isillustrated in FIG. 4. Note that the particular embodiments ofsubstations and positions thereof may vary from those described belowand illustrated in FIG. 4. Further, the particular operations employedas well as the order thereof may also vary. In this regard, theequipment employed to assemble a cartridge may depend on the particularconfiguration of the end-product cartridge. In this regard, thecartridge 200 described above and referenced hereinafter is discussedfor example purposes only. Additionally, although the descriptiongenerally refers to the portions of the cartridge assembly subsystem 402as substations, it should be understood that the various assemblyoperations discussed herein may be performed by a single device,apparatus, or substation, or distributed across multiple devices,apparatuses, and substations. Accordingly, the description providedbelow is for example purposes only, and the equipment and operations andorder thereof employed may vary without departing from the scope of thedisclosure. Further, it should be understood that various substationsand operations performed at each of the substations should be viewed asindividual inventive aspects. In this regard, although the individualsubstations and operations are generally described herein as being partof a system, each of the substations may operate independently of theother substations discussed herein and/or be combined with othersubstations.

By way of example, the cartridge assembly subsystem 402 may include abase load substation 502, a terminal coupling substation 504, a terminalsealing substation 506, a control component coupling substation 508, aflow tube coupling substation 510, a heating element coupling substation512, a liquid transport element bending substation 514, a reservoircoupling substation 516, and an outer body coupling substation 518. Asillustrated, the controller 417 may be configured to control one or moreof the substations 502-518 of the cartridge assembly subsystem 402.Briefly, the base load substation 502 may be configured to receive abase (e.g., the base 204) and orient the base for assembly with thevarious other components of the cartridge. The terminal couplingsubstation 504 may be configured to couple one or more terminals (e.g.,the first and second heating terminals 234 a,b and the control componentterminal 206) to the base. The terminal sealing substation 506 may beconfigured to seal one or more of the terminals with respect to the baseto prevent fluid ingress or egress between the base and the terminal(s).The control component coupling substation 508 may be configured tocouple a control component (e.g., the electronic control component 208)to the control component terminal. The flow tube coupling substation 510may be configured to couple a flow tube (e.g., the flow tube 210) to thecontrol component, the first and second heating terminals, and/or othercomponents. The heating element coupling substation 512 may beconfigured to couple a heating element (e.g., the heating element 240)to the heating terminals. The liquid transport element bending station514 may be configured to bend a liquid transport element (e.g., theliquid transport element 238) about the heating terminals. The reservoircoupling substation 516 may be configured to couple a reservoirsubstrate (e.g., the reservoir substrate 214) to the liquid transportelement. Further, the outer body coupling substation 518 may beconfigured to couple an outer body (e.g., the outer body 216) to thebase.

The cartridge assembly subsystem 402 may assemble the cartridge (e.g.,the cartridge 200) in a variety of manners. For example, in oneembodiment the cartridge may be assembled generally upwardly from abase. In other words, components may be inserted into or otherwisecoupled to the base to build up the cartridge therefrom.

In this regard, as illustrated in FIGS. 5 and 6, in one embodiment atransport system may include carriages 600, which may also be referredto as “pods” or “nests,” which may be employed to assemble thecartridges 200. FIG. 5 illustrates an empty carriage 600, whereas FIG. 6illustrates the carriage after a base 204 is loaded therein. Asillustrated, the carriages 600 may include a clamping mechanism 602. Theclamping mechanism 602 may include a displaceable piston 604 defining ahead 606 at an end thereof. A biasing mechanism may bias thedisplaceable piston 604 toward a groove 608. Accordingly, as illustratedin FIG. 6, the head 606 of the displaceable piston 604 may cooperatewith the groove 608 to retain the base 204 therein. In this regard, thegroove 608 may be V-shaped in order to center the base 204 in thegroove.

Various embodiments of biasing mechanisms may be employed, such asmagnets, hydraulic or pneumatic cylinders, etc. However, in theillustrated embodiment a rod 610 may be received in a mount 612. Themount 612, which may also function to align the piston 604 with respectto the groove 608, may include a spring therein that biases the rod 610toward the head 606 of the piston. Accordingly, the head 606 of thepiston 604 may be biased toward the groove 608 to retain the base 204therein. Further, the piston 604 may include a handle 614 at an endthereof opposite from the head 606. The handle 614 may be configured toallow for grasping thereof, via automated or manual methods, to opposethe force provided by the biasing mechanism to thereby release the base204.

The transport system may further comprise a rail 616 or other mechanismconfigured to provide for movement of the carriages between a pluralityof substations. The carriages 600 may be mounted to the rail 616 usingwheels 618 (see, e.g., FIG. 5). The carriages 600 may be moved along therail 616 by driving the wheels 618. Alternatively, magnetic propulsionmay be employed to move the carriages 600. However, the wheels 618 maystill be provided in order to hold the carriages on the rail 616. Inthis regard, as illustrated in FIGS. 7 and 8, a magnetic track 620 maycause the carriage 600 to move. More particularly, the carriage 600 mayfurther comprise a magnet 622. The magnetic track 620 may changepolarity in relation to the position of a magnet 622 coupled to thecarriage 600 such that attractive and/or repulsive forces between themagnetic track 620 and the magnet cause the carriage to move. Thus, thecarriages 600 may be transferred between various substations. In thisregard, a plurality of the carriages 600 may be provided. The carriages600 may be configured to move between the various substations describedhereinafter. In this regard, the carriages 600 may be disposed atvarious locations along the path defined by the rail during assembly ofthe cartridges such that any given time, the carriages may bedistributed along the length of the rail. Thereby, multiple cartridgesmay be constructed simultaneously.

It may be desirable to stop or slow down movement of the carriages 600at one or more of the substations while one or more operations areconducted in order to simplify coupling parts of the cartridge to thebase. Further, in some embodiments it may be desirable to lock thecarriages 600 in a predefined position to substantially prevent movementof the carriages at one or more of the substations. In this regard,magnetic locking of a position of the carriage may be insufficient toproperly lock a carriage in place because magnetic locking may stillallow for some movement of the carriage. Accordingly, a lockingapparatus may be employed to temporarily restrain movement of eachcarriage 600 along the rail 616.

The locking apparatus may include a locator mechanism 624 coupled toeach carriage 600. In the illustrated embodiment, the locator mechanism624 comprises first and second pegs 626. Further, the locking apparatusmay comprise an engagement mechanism 628, which may be positioned ateach location at which locking the carriage 600 in place is desired.Thus, the engagement mechanism 628 may be located at a fixed positionrelative to the longitudinal length of the rail 616. However, theengagement mechanism 628 may be configured to move into contact with thelocator mechanism 624 (e.g., via a pneumatic piston, hydraulic piston,or linear motor) to lock the carriage 600 in place.

In the illustrated embodiment, the engagement mechanism 628 comprises acylinder 630. Accordingly, as the engagement mechanism 628 is directedupwardly, the cylinder 630 may contact one or both of the pegs 626 ofthe locator mechanism 624. Thereby, the pegs 626 may deflect from thecylinder 630 such that the locator mechanism 624 becomes centered withrespect to the engagement mechanism 628. Further, in one embodiment thecylinder 630 may comprise a roller or wheel configured to rotate tofacilitate centering between the pegs 626 by allowing the cylinder torotate when brought into contact with one of the pegs, rather thanscraping thereagainst. Regardless of whether or not the cylinder 630rotates, any imprecision in the initial stopping point of the carriage600 may be accounted for by the centering effect created by theinteraction between the pegs 626 of the locator mechanism 624 and thecylinder of the engagement mechanism 628. Accordingly, movement of thecarriage 600 along the rail 616 may be restrained by interaction betweenthe fixed engagement mechanism 628 and the locator mechanism 624 coupledto the carriage.

Note that locking apparatus may comprise various other mechanismsconfigured to center the carriage with respect to the engagementmechanism. For example, the locator mechanism may comprise a verticallyoriented groove. Alternatively or additionally, the engagement mechanismmay comprise an angled member such as a triangle.

Accordingly, the carriages 600 may be employed to transport the base 204to various substations at which various components are assembledthereto. Thereby, the base 204 may be loaded into the carriage 600 asillustrated in FIGS. 6 and 8 at the base load substation 502.Thereafter, other components may be assembled with the base 204 (e.g.,by directing the components downwardly into contact with the base) toassemble the cartridge.

In this regard, as described above, the control component terminal 206and the first and second heating terminals 234 a,b may be inserted intothe base 204 at the terminal coupling substation 504. In someembodiments the first heating terminal 234 a, the second heatingterminal 234 b, and/or the control component terminal 206 may beprovided from substantially continuous inputs. More particularly, thefirst heating terminal 234 a may be supplied from a substantiallycontinuous first heating terminal input, the second heating terminal 234b may be supplied from a substantially continuous second heatingterminal input, and/or the control component terminal 206 may besupplied from a substantially continuous control component terminalinput. Note that the term substantially continuous, as used herein inrelation to certain specified inputs, refers to a configuration in whichthe referenced input defines a strip, chain, or other grouping ofinterconnected underlying components such that individual components maybe singulated therefrom.

By way of example, FIG. 9 illustrates a substantially continuous firstheating terminal input 700 comprising a plurality of the first heatingterminals 234 a. In this regard, each of the first heating terminals 234a is connected to a substantially continuous carrier 702. In theillustrated embodiment, each of the first heating terminals 234 a areconnected to the carrier 702 by first and second couplers 704. However,a single coupler or additional couplers may be employed to hold thefirst heating terminals 234 a to the carrier 702 in other embodiments.In some embodiments, as illustrated, the first heating terminals 234 a,the couplers 704, and the carrier 702 may be integrally formed (e.g.,from a strip of sheet metal).

The couplers 704 may be cut to release an individual first heatingterminal 234 a from the substantially continuous first heating terminalinput 700. Further, the carrier 702 may comprise apertures 706, grooves,cutouts, or other mechanisms configured to facilitate movement of thesubstantially continuous first heating terminal input 700 such thatindividual first heating terminals 234 a may be removed therefrom. Inthis regard, as illustrated in FIG. 9, a wheel 708 may includeprotrusions 710 configured to engage the apertures 706, such thatrotation of the wheel 708 causes movement of the input 700 toward alocation at which there individual first heating terminals 234 a areremoved therefrom. Note that although the above-provided description hasbeen provided in terms of the first heating terminal 234 a, in someembodiments the second heater terminal 234 b and/or the controlcomponent terminal 206 may be supplied via substantially continuousinputs in similar manners.

After insertion into the base 204, the terminal sealing substation 506may seal one or more of the terminals 206, 234 a,b with respect to thebase, in some embodiments, in order to prevent liquid ingress or egresspast the terminals. However, in some embodiments only the heatingterminals 234 a,b may be sealed. For example, in the illustratedembodiment the control component terminal 206 may extend through, or bepositioned adjacent to, an opening through the base 204 through which auser draws air through the cartridge 200 during use thereof.Accordingly, the control component terminal 206 may not be sealed withrespect to the base 204 in order to prevent blocking the openingextending through the base. Further, the control component terminal 206may not be in contact with the liquid-filled reservoir substrate 214,such that liquid egress past the control component terminal 206 may notbe of concern.

FIG. 10 illustrates an example embodiment of the terminal sealingsubstation 506. The terminal sealing substation 506 may include one ormore sealant dispensers 802 a,b. In the illustrated embodiment first andsecond sealant dispensers 802 a,b are employed to dispense a sealantprovided by a pump 804 through one or more conduits 806. A robotic arm808 may grasp the base 204 with a gripper 810. In this regard, therobotic arm 808 may position the base 204 such that the base ispositioned in front of nozzles 812 a,b of the sealant dispensers 802a,b. For example, the gripper 810 may grasp an external surface of thebase 204 and remove the base 204 from the carriage 600. Thereafter, therobotic arm 808 may position the base 204 such that the terminals 206,234 a,b extend generally upwardly in a position proximate the sealantdispensers 802 a,b. By grasping the outside of the base 204 in thismanner, the gripper 810 of the robotic arm 808 may not interfere withdispensing the sealant because the gripper may not be positioned betweenthe nozzles 812 a,b and the terminals 206, 234 a,b extending upwardlyfrom the base.

As illustrated in FIG. 11, the sealant dispensers 802 a,b may bepositioned such that the nozzles 812 a,b are at least partially directedtoward one another. Thereby, the robotic arm 808 may position the base204 and the terminals 206, 234 a,b between the sealant dispensers 802a,b such that nozzles 812 a,b may direct a sealant at opposing sides ofthe terminals. For example, droplets of the sealant may be ejected fromthe nozzles 812 a,b toward opposing sides of the heating terminals 234a,b. More particularly, the nozzles 812 a,b may direct the droplets ofthe sealant at an interface between the heating terminals 234 a,b andthe base 204.

In some embodiments the sealant may comprise a hot melt adhesivecomprising polyolefins including atactic polyalphaolefins, polyurethane,ethylene-vinyl acetate (EVA), metallocene polyalphaolefins, blockcopolymers, and/or polyamides. Thus, the terminal sealing substation 506may further comprise a heater 814 (see, FIG. 10), which may melt thesealant. Further, the conduits 806 may be heated and/or insulted. Sealsin the pump 804 and the sealant dispensers 802 a,b may traditionallyemploy TEFLON® brand material for lubrication. However, a food-gradegrease or lubricant may instead be employed in some embodiments, inorder to advantageously employ food-grade manufacturing techniques inthe production of the cartridge.

After the droplets of the liquid sealant contact the heating terminals234 a,b and/or the base 204, the droplets may dry in place relativelyquickly. Further, the droplets may not contact one another. Thus, acomplete seal around the full interface of the heating terminals 234 a,bwith the base 204 may not be formed by the initial application of thedroplets of the sealant. Accordingly, the terminal sealing substation506 may further comprise a re-melting device such as a hot air gun 816configured to direct a flow of heated air at the sealant afterapplication thereof to the heating terminals 234 a,b and/or the base204. Accordingly, the hot air from the hot air gun 816 may re-melt thesealant and blow the melted sealant around the heating terminals 234 a,bsuch that the interface between the heating terminals and the base 204is fully sealed around the perimeter of each of the heating terminals.In this regard, the hot air gun 816 may move relative to the base 204and the heating terminals 234 a,b. In some embodiments the hot air gun816 may be configured to move. However, as illustrated, in anotherembodiment the hot air gun 816 may be stationary. Accordingly, therobotic arm 804 may move the base 204 relative to the hot air gun 816such that hot air re-melts the sealant and directs the sealant aroundthe interface between the heating terminals 234 a,b and the base. Thus,the sealant may re-solidify and seal any gaps between the heatingterminals 234 a,b and the base 204.

Note that the terminal sealing substation 506 may additionally oralternatively seal the control component terminal 206 and/or any othercomponent of the cartridge 200 with respect to the base 204.Additionally, although the re-melting device is described above as beingthe hot air gun 816, in other embodiments the sealant may be re-meltedby other methods and other re-melting devices, such as by applyingultrasonic vibrations with an ultrasonic vibration device and/orapplying radiant heat with a radiant heater. Further, although thesealant is described above as being a hot melt adhesive, various otherembodiments of sealants may be employed. For example, the sealant maycomprise an epoxy or an electrical potting material. After the heatingterminals 234 a,b are sealed, the base 204 may be returned to thecarriage 600 by the robotic arm 608.

Thereafter, the control component coupling substation 508 may couple theelectronic control component 208 to the control component terminal 206(e.g., by vertically inserting the control component into a slot definedby the control component terminal). Then the flow tube couplingsubstation 510 may couple the flow tube 210 to the partially assembledcartridge. For example, the flow tube 210 may be inserted horizontally,such that the heating terminals 234 a,b are slightly spread apart andthen snap into place in longitudinal grooves defined in the flow tube,with a horizontal slot in the flow tube engaging the top of theelectronic control component 208.

Next, the partially assembled cartridge may be transported to theheating element coupling substation 512 at which the heating element 240may be coupled to the heating terminals 234 a,b. In this regard, FIG. 12illustrates an example embodiment of the heating element couplingsubstation 512. In the illustrated embodiment, the heating elementcoupling substation 512 includes a preparing portion 902, a weldingportion 904, and a transport apparatus 905 configured to transport anindividual heating element 240 wrapped about a liquid transport element238 from the preparing portion 902 to the welding portion 904.

As illustrated in FIG. 13, in some embodiments the heating element andthe liquid transport element may be supplied from a substantiallycontinuous heating element input 906. In this regard, the substantiallycontinuous heating element input 906 may comprise a plurality of theheating elements 240 wound about the liquid transport element 238.Examples of heating elements wound about liquid transport elements areprovided in U.S. patent application Ser. No. 13/827,994, filed Mar. 14,2013 and Ser. No. 13/708,381, filed Dec. 7, 2012, which are incorporatedherein by reference in their entireties.

As illustrated, the substantially continuous heating element input 906may be supplied from a spool 908 in some embodiments. The spool 908 maypassively rotate as the substantially continuous heating element input906 is pulled therefrom. Alternatively, the spool 908 may be activelyrotated (e.g., by a motor) such that the spool rotates as thesubstantially continuous heating element input 906 is pulled therefrom.By either actively rotating the spool 908 or passively allowing thespool to substantially freely rotate as the substantially continuousheating element input 906 is pulled therefrom, tension in thesubstantially continuous heating element input may be controlled. Inthis regard, applying too much tension to the substantially continuousheating element input 906 may damage the heating elements 240 or theliquid transport element 238. For example, spacing of the coils of theheating elements 240 may be altered, which may make it difficult toattach the heating elements to the heating terminals. Further, too muchtension in the liquid transport element 238 may cause breakage thereof,or stretching of the liquid transport element may reduce the diameterthereof and affect the ability of the liquid transport element to drawthe aerosol precursor composition to the heating element 240.Accordingly, the substantially continuous heating element input 906 maybe supplied to the preparing portion 902 without damaging the heatingelements 240 or the liquid transport element 238 by controlling thetension therein.

FIG. 14 illustrates an enlarged view of the preparing portion 902 of theheating element coupling substation 512. Briefly, the preparing portion902 of the heating element coupling substation 512 may be configured toprepare an individual heating element 240 coupled to an individualliquid transport element 238 for welding at the welding portion 904 ofthe heating element (see, e.g., coupling substation 512. In this regard,the preparing portion 902 of the heating element coupling substation 512may be configured to singulate one heating element 240 and one liquidtransport element 238, such that the heating element may thereafter becoupled to the heating terminals. In this regard, in one embodimentindividual heating elements and liquid transport elements may bedelivered to the preparing portion in a form ready for attachment to theheating terminals without performing additional operations thereon.

However, as described above, in the illustrated embodiment thesubstantially continuous heating element input 906 may include a coil ofwire wrapped about a substantially continuous liquid transport element.Thereby, the substantially continuous heating element input 906 may becut to remove an individual heating element 240 and liquid transportelement 238 therefrom. In this regard, as illustrated, the preparingportion 902 of the heating element coupling substation 512 may include adispenser 910, a cutter 912, and an imaging device 914 (e.g., a camera).

FIG. 15 schematically illustrates the preparing portion 902 of theheating element coupling substation 512. The dispenser 910 may beconfigured to dispense a length of the substantially continuous heatingelement input 906 from the spool 908 (see, FIG. 13). In this regard, thedispenser 910 may comprise a stationary portion 916 and a moveableportion 918. The moveable portion 918 may include a clamp 920 configuredto grasp the substantially continuous heating element input 906proximate an end thereof. The moveable portion 918 may be configured tomove relative to the stationary portion 916 in a direction 922 such thatthe substantially continuous heating element input 906 is dispensed fromthe spool 908 (see, FIG. 13). For example, the dispenser 910 maycomprise a hydraulic or pneumatic cylinder or a linear motor in someembodiments. The dispenser 910 may be configured to pull on thesubstantially continuous heating element input 906 until a desiredlength thereof has been dispensed.

In this regard, the imaging device 914 may be positioned and configuredto capture images of the substantially continuous heating element input906 as it is dispensed. The controller 417 (see, e.g., FIG. 3) may be incommunication with the imaging device 914 and configured to analyze theimages captured by the imaging device. Accordingly, the controller 417may be configured to analyze the images captured by the camera 914 toidentify the position of the substantially continuous heating elementinput 906 to determine a dispensed length thereof.

In this regard, the dispenser 910 may be configured to start dispensingthe substantially continuous heating element input 906 and thecontroller 417 may analyze the images thereof and direct the dispenserto stop dispensing the substantially continuous heating element inputwhen a desired length thereof has been dispensed. For example, thecontroller 417 may be configured to analyze the image captured by theimaging device 914 to detect coils or other features of the heatingelement 240. By way of further example, in one embodiment the controller417 may be configured to detect a first contact portion 926 and a secondcontact portion 928 of the heating element 240, which are configured toengage the heating terminals. In one embodiment, the controller 417 maydetermine the position of inner edges 926 a, 928 a of the contactportions 926, 928 of the heating element 240. Thereby, the controller417 may calculate a midpoint between the contact portions 926, 928 ofthe heating element 240 and allow the dispenser 910 to continuedispensing the substantially continuous heating element input 906 untilthe midpoint between the first contact portion 926 and the secondcontact portion 928 is aligned with the midpoint of the imaging device914.

At this time, the controller 417 may direct the dispenser 910 to stopdispensing the substantially continuous heating element input 906.Additionally, the controller 417 may direct a transport apparatus 905 tograsp the substantially continuous heating element input 906. Forexample, the transport apparatus 905 may comprise a clamp 930 includingfirst and second arms 932 a, 932 b configured to grasp the substantiallycontinuous heating element input 906 outside of the contact portions926, 928 of the heating element 240, which may allow the clamp tocontinue to hold the heating element during welding, as discussed below.

Further, the controller 417 may direct the cutter 912, which maycomprise first and second blades 934 a, 934 b, to cut the substantiallycontinuous heating element input 906 to singulate a heating element 240and liquid transport element 238 having a desired length. In thisregard, the imaging device 914 may be positioned such that when themidpoint between the first contact portion 926 and the second contactportion 928 of the heating element 240 is aligned with the midpoint ofthe imaging device, a distance between an end of the substantiallycontinuous heating element input 906, as held by the clamp 920, and theblades 934 a, 934 b of the cutter 912 is equal to a desired length of asingle heating element 240 and liquid transport element 238.

Note that the preparing portion 902 of the heating element couplingsubstation 512 may further comprise a tube 936. The substantiallycontinuous heating element input 906 may be supplied through the tube936 to the cutter 912. Accordingly, after the substantially continuousheating element input 906 is cut, the tube 936 may support thesubstantially continuous heating element input proximate a new endthereof. Thereby, the clamping mechanism 910 of the transport apparatus905 may release from the singulated heating element 240 and liquidtransport element 238 and grasp the new end of the substantiallycontinuous heating element input 906, such that the above-describedoperations may be repeated by the preparing portion 902 of the heatingelement coupling substation 512, as illustrated in FIG. 16.

As further illustrated in FIG. 16, after a heating element 240 andliquid transport element 238 is singulated, the transport apparatus 905may direct the heating element and liquid transport element to thewelding portion 904 (see, e.g., FIG. 17). In this regard, the transportapparatus 905 may comprise a robotic arm 938 configured to move theclamp 930 between the preparing portion 902 and the welding portion 904of the heating element coupling substation 512. Accordingly, the clamp930 of the transport apparatus 905 may grasp the heating element 240 andliquid transport element 238 at the preparing portion 902 and continueto hold the heating element and liquid transport element whentransported to the welding portion 904.

FIG. 17 illustrates the welding portion 904 of the heating elementcoupling substation 512. As illustrated, the welding portion 904 mayinclude a laser 940, an imaging device 942 (e.g., a camera), a terminalfixation mechanism 944, and a gas dispenser 946. Briefly, the laser 940may be configured to produce a laser beam to weld the heating element240 to heating terminals. The imaging device 942 may be configured tocapture images of the heating element 240 and the heating terminals. Theterminal fixation mechanism 944 may be configured to grasp the firstheating terminal and the second heating terminal during welding. The gasdispenser 946 may be configured to dispense an inert gas (e.g., argon)to improve the resultant weld (e.g., by preventing oxidation thereof).

Note that although the heating element is described herein as beingattached to the heating terminals via laser welding, various other typesof welding may be employed, such as arc welding, metal inert gas welding(MIG), tungsten inert gas welding (TIG), plasma welding, etc. Morebroadly, the heating element may be attached to the heating terminalsvia other methods, such as soldering and mechanical connections.Accordingly, it should be understood that various other embodiments ofcoupling methods and related equipment may be employed without departingfrom the scope of the present disclosure.

As described above, carriages 600 may travel along a rail 616 to varioussubstations. In this regard, as further illustrated in FIG. 17, the rail616 and magnetic track 620 may extend to and past the welding portion904 of the heating element coupling substation 512 in some embodiments.Accordingly, the carriages may deliver the base, with heating terminalscoupled thereto, to the welding portion 904 of the heating elementcoupling substation 512. For example, as described above, the heatingterminals, control component terminal, control component, and flow tubemay be assembled to the base when the carriages reach the weldingportion 904 of the heating element coupling substation 512.

However, in order to facilitate welding the heating terminals to theheating element, it may be desirable to align the heating terminals in adesired configuration. In this regard, as illustrated in FIG. 18, theterminal fixation mechanism 944 may comprise first and secondcooperating portions 948 a, 948 b. The cooperating portions 948 a, 948 bof the terminal fixation mechanism 944 may be configured to grasp thefirst heating terminal and the second heating terminal such that a firstheating terminal tab and a second heating terminal tab thereof aresubstantially coplanar. Alternatively, or additionally, the cooperatingportions 948 a, 948 b of the terminal fixation mechanism 944 may beconfigured to adjust a spacing between the first heating terminal andthe second heating terminal. As illustrated, the cooperating portions948 a, 948 b of the terminal fixation mechanism 944 may respectivelydefine a groove 950 configured to receive the heating terminals therein.

FIGS. 19-21 schematically illustrate operation of the terminal fixationmechanism 944. FIG. 19 illustrates the cooperating portions 948 a, 948 bof the terminal fixation mechanism 944 in an initial separatedconfiguration. The initial separated configuration may allow the heatingterminals 234 a, 234 b to be received between the cooperating portions948 a, 948 b thereof. Thereafter, as illustrated in FIG. 20, one or bothof the cooperating portions 948 a, 948 b may move such that thecooperating portions move toward one another. As the cooperatingportions 948 a, 948 b move relatively toward each other, the grooves 950may cooperate to adjust the spacing between the heating terminals 234 a,234 b. For example, the heating terminals 234 a, 234 b may be movedtoward one another, as illustrated. Accordingly, as illustrated in FIG.21, the spacing of the heating terminals 234 a, 234 b may be adjusted tomatch a desired spacing when the cooperating portions 948 a, 948 b clampagainst opposing sides of the heating terminals. Further, by clampingthe heating terminals 234 a, 234 b on opposing sides between thecooperating portions 948 a, 948 b, the heating terminals may be held bythe terminal fixation mechanism 944 such that heating terminal tabsthereof are coplanar, which may facilitate welding of the heatingelement thereto.

Note that in the embodiment illustrated in FIGS. 19-21, the grooves 950defined in the cooperating portions 948 a, 948 b are configured to movethe heating terminals 234 a, 234 b toward one another. However, inanother embodiment, as illustrated in FIG. 22, the terminal fixationmechanism 944′ may include first and second cooperating portions 948 a′,948 b′ including grooves 950′ that are configured to adjust the spacingbetween heating terminals 234 a, 234 b by moving each of the heatingterminals either toward or away from the other heating terminal,depending on the initial position of the heating terminals. Accordingly,the heating terminals 234 a may be centered by providing grooves 950′configured to move each heating terminal 234 a, 234 b in either of twodirections. Alternatively, as may be understood, the grooves may beconfigured to only move the terminals away from one another in anotherembodiment. Thus, the selection of the particular shape andfunctionality of the grooves of the cooperating portions of the terminalfixation mechanism may depend on the initial configuration of theheating terminals at the time the base and heating terminals reach theterminal heating element coupling substation 512.

While the heating terminals 234 a, 234 b are clamped in plane at adesired spacing using the terminal fixation mechanism 944, the transportapparatus 905 may hold the singulated heating element 240 and liquidtransport element 238 with the clamp 930 such that the heating elementis in view of the imaging device 942 (see, FIG. 17). For example, asillustrated in FIG. 23, the clamp 930 may initially hold the heatingelement 240 and liquid transport element 238 above the heating terminals234 a, 234 b such that the heating element is in view of the imagingdevice 942 and thereby the imaging device may determine the position ofthe heating element. By way of further example, as described above, thecontroller 417 (see, e.g., FIG. 3) or a separate controller maydetermine the position of the inner edges 926 a, 928 a of the contactportions 926, 928 of the heating element 240 from the images captured bythe imaging device 942. Accordingly, the midpoint between the contactportions 926, 928 of the heating element 240 may be determined.

Similarly, the location of the heating terminals 234 a, 234 b may bedetermined. In this regard, as illustrated in FIG. 23, the heatingterminals 234 a, 234 b may respectively comprise a heating terminal tab952 a, 952 b at an end thereof configured to be welded to one of thecontact portions 926, 928 of the heating element 240. Accordingly, thepositions of the heating terminal tabs 952 a, 952 b may be determined.For example, inner edges 954 a, 954 b of the heating terminals 234 a,234 b may be identified by the controller 417 (or another controller)from the images captured by the imaging device 942. Thereby, thecontroller 417 may determine the midpoint between the heating terminaltabs 952 a, 952 b.

Thus, the transport apparatus 905 may move the heating element 240 andthe liquid transport element in position for welding the heating elementto the heating terminals 234 a, 234 b. In this regard, the controller417 may direct the transport apparatus 905 to align the midpoint betweenthe first heating terminal tab 952 a and the second heating terminal tab952 b with the midpoint between the first contact portion 926 and thesecond contact portion 928. Further, the controller 417 may direct thetransport apparatus 905 to bring the heating element 240 into engagementwith the heating terminal tabs 952 a, 952 b. In particular, thetransport apparatus 905 may engage the first contact portion 926 of theheating element 240 with the first heating terminal tab 952 a and engagethe second contact portion 928 with the second heating terminal tab 952b. In some embodiments the controller 417 may direct the transportapparatus 905 to press the heating element 240 against the heatingterminal tabs 952 a, 952 b such that the heating terminals 234 a, 234 bare displaced slightly (e.g., a distance from about 0.002 inches toabout 0.006 inches, and preferably about 0.004 inches). In this regard,by pressing the heating element 240 against the heating terminal tabs952 a, 952 b (e.g., in a direction perpendicular to a substantiallyplanar front face thereof, contact between the heating element and theheating terminals 234 a, 234 b may be assured.

Accordingly, as illustrated in FIG. 24, the laser 940 may weld theheating element 240 to the heating terminals 234 a, 234 b. The laser 940may weld the heating element 240 to the first heating terminal 234 a andthe second heating terminal 234 b by directing a laser beam at the firstheating terminal tab 952 a and at the second heating terminal tab 952 b.As illustrated in FIG. 24, the laser beams may be directed at a backsideof the first heating terminal tab 952 a and the second heating terminaltab 952 b opposite from the heating element 240. Accordingly, energyfrom the laser beams may heat the heating terminal tabs 952 a, 952 b tocause the heating terminal tabs to weld to the contact portions 926, 928of the heating element, thereby completing the atomizer 202 (see, e.g.,FIG. 1). In the illustrated embodiment, the laser is directed at firstand second locations 956 a, 956 b on each heating terminal tab 952 a,952 b to provide a relatively more secure weld. However, the laser beamsmay be directed at a greater or lesser number of locations in otherembodiments. Note that by directing the laser beams at the heatingterminal tabs 952 a, 952 b, issues with respect to damaging the heatingelement 240 may be avoided by indirectly, rather than directly applyingheat to the heating element.

Note that the heating element 240 illustrated in FIG. 23 comprises awire defining a variable coil spacing. The variable coil spacing may beemployed to provide the contact portions 926, 928 with a relativelytight coil spacing. This relatively tight coil spacing at the contactportions 926, 928 may facilitate welding the heating terminals 234 a,234 b thereto by providing more wire material at these locations towhich the heating terminals may be affixed.

A center portion 929 of the heating element 240, defined between thecontact portions 926, 928, may function to produce heat when current issupplied therethrough via the heating terminals 234 a, 234 b. Thespacing of the coils at the center portion 929 of the heating element240 may be greater than the spacing of the coils at the contact portions926, 928 since the center portion is not employed for affixation to theheating terminals 234 a, 234 b. However, the spacing of the coils at thecenter portion 929 of the heating element 240 may be less than a spacingof optional coils at outer portions 931 a, 931 b of the wire positionedoutside of the contact portions 926, 928 of the heating element. In thisregard, the outer portions 931 a, 931 b may not produce heat orfacilitate affixation to the heating terminals 234 a, 234 b, and hencethe spacing of the coils may be relatively large in order to decreasematerial usage of the wire in the formation of the heating element 240.Rather, the outer portions 931 a, 931 b may be provided for ease ofmanufacturing the substantially continuous heating element input 906(see, e.g., FIG. 13) in some embodiments. Various other details withrespect to atomizers employing variable coil spacing are provided inU.S. patent application Ser. No. 13/827,994, filed Mar. 14, 2013, which,as noted above, is incorporated herein by reference in its entirety.

Note further that the above-described coil spacing, which may beapplicable to any of the atomizers described herein, may not be uniformthroughout each portion of the wire. In this regard, some variation mayexist in the coil spacing in one or more of the portions of the wire.For example, the spacing of the coils may vary across the center portionof the heating element. Accordingly, by way of further example, thedifferences in coil spacing described above may refer to the averagecoil spacing for each of the portions of the wire.

Following welding, the carriage 600 with the partially assembledcartridge 200 may be directed to the liquid transport element bendingsubstation 514. The liquid transport element bending substation 514 maybe configured to bend the liquid transport element 238 such that theends thereof extend down the heating element terminals 234 a, 234 b.However, the liquid transport element 238 and/or the wire wound thereonmay be somewhat resilient and tend to bend back to an initial straightconfiguration following bending thereof.

In this regard, as illustrated in FIG. 25, in some embodiments thecarriages 600 may further comprise pivotable arms 632 a, 632 bconfigured to engage the ends of the liquid transport element 238 suchthat the ends of the liquid transport element are held against theheating terminals 234 a, 234 b. In this regard, the pivotable arms 632a, 632 b may be configured to apply a force to the liquid transportelement 238 to hold the liquid transport element against the heatingterminals 234 a, 234 b. For example, magnets and/or a spring may beconfigured to bias each of the pivotable arms 632 a, 632 b toward theliquid transport element 238. In this regard, in the illustratedembodiment, the pivotable arms 632 a, 632 b may include magnetic members634 a, 634 b that cooperate with stationary magnetic base members 636 a,636 b of the carriage 600 to bias the pivotable arms 632 a, 632 bagainst the liquid transport element 238. However, various other biasingmechanisms may be employed in other embodiments.

Following bending of the liquid transport element 238 and retention ofthe liquid transport element in the bent configuration with thepivotable arms 632 a, 632 b, the carriage 600 may be directed to thereservoir coupling substation 516. As illustrated in FIG. 26, thereservoir coupling substation 516 may include a spool 1002. The spool1002 may be configured to supply a substantially continuous reservoirsubstrate input 1004 from which individual reservoir substrates may becut. Tension in the substantially continuous reservoir substrate input1004 may be controlled to prevent stretching the reservoir substratematerial, which may affect the liquid storage and transportcharacteristics thereof. In this regard, rather than being pulled fromthe spool 1002, the substantially continuous reservoir substrate input1004 may be actively dispensed from the spool 1002 (e.g., by a belt1006) in some embodiments. However, the substantially continuousreservoir substrate input 1004 may be passively dispensed in otherembodiments.

FIGS. 27 and 28 illustrate singulation of individual reservoirsubstrates from the substantially continuous reservoir substrate input1004 supplied from the spool 1002. In this regard, as illustrated, thereservoir coupling substation 516 may further comprise a moveable clamp1008 and a stationary clamp 1009. The moveable clamp 1008 may beconfigured to pull a predefined quantity of the substantially continuousreservoir substrate input 1004 downwardly into a cutter 1010. In thisregard, FIG. 27 illustrates the moveable clamp 1008 at an upper limit,where it grips the substantially continuous reservoir substrate input1004. FIG. 28 illustrates the moveable clamp 1008 at a lower limit. Whenthe moveable clamp 1008 reaches the lower limit, the moveable clamp hasmoved a predefined length of the substantially continuous reservoirsubstrate input 1004 into the cutter 1010, which cuts the substantiallycontinuous reservoir substrate input to define an individual reservoirsubstrate having a desired length.

Further, when the moveable clamp 1008 reaches the lower limit, thestationary clamp 1009 grips the substantially continuous reservoirsubstrate input 1004. Accordingly, the substantially continuousreservoir substrate input 1004 is prevented from moving during cuttingthereof into an individual reservoir having a desired length. Further,the stationary clamp 1009 may prevent undesirable upward movement of thesubstantially continuous reservoir substrate input 1004 by continuing tohold the substantially continuous reservoir substrate input as themoveable clamp 1008 returns to the upper limit. Once the moveable clamp1008 reaches the upper limit and grips the substantially continuousreservoir input 1004, the stationary clamp 1009 may release thesubstantially continuous reservoir substrate input to allow the moveableclamp to pull the predefined quantity of the substantially continuousreservoir substrate input downwardly into the cutter 1010, as describedabove.

Following singulation, a transfer mechanism 1012 may receive thereservoir substrate. As illustrated in FIGS. 28 and 29, the transfermechanism 1012 may include a head portion 1014 configured to releasablyretain the reservoir substrate. In some embodiments the head portion1014 of the transfer mechanism 1012 may be configured to apply vacuum tothe reservoir substrate thereon. In this regard, the head portion 1014may define a plurality of apertures to which vacuum is applied. However,in other embodiments the reservoir may be retained on the transfermechanism 1012 by a clamp or other mechanical mechanisms.

As illustrated in FIG. 29, the transfer mechanism 1012 may be configuredto receive the reservoir substrate from the cutter 1010 and transportthe reservoir substrate to a wrapping mechanism 1016. In this regard,the transfer mechanism 1012 may travel along a longitudinal path 1018and then a lateral path 1020 to transfer the reservoir substrate to thewrapping mechanism 1016. The wrapping mechanism 1016 may comprise a headportion 1022 configured to receive the reservoir substrate. The headportion 1022 of the wrapping mechanism 1016 may employ vacuum to holdthe reservoir substrate. In this regard, the head portion 1022 of thewrapping mechanism 1016 may define a plurality of apertures at an innersurface thereof to which vacuum is applied. In some embodiments, duringtransfer of the reservoir substrate from the head portion 1014 of thetransfer mechanism 1012 to the head portion 1022 of the wrappingmechanism 1016, vacuum at the head portion of the transfer mechanism mayswitch to a positive pressure. Accordingly, air directed out of the headportion 1014 of the transfer mechanism 1012 may push the reservoirsubstrate toward the head portion 1022 of the wrapping mechanism 1016which may securely engage the reservoir substrate using vacuum appliedthereto.

After receiving the reservoir substrate from the transfer mechanism1012, the wrapping mechanism 1016 may spin around (e.g., about 180degrees) such that the head portion 1022 thereof is positioned proximatethe rail 616, as illustrated in FIG. 30. In this regard, the carriage600 may deliver the partially assembled cartridge to the reservoircoupling substation 516. For example, the partially assembled cartridgemay define the configuration described above and illustrated in FIG. 25in which the liquid transport element 238 is bent and held in place bythe pivotable arms 632 a, 632 b.

FIGS. 30-32 illustrate movement of portions of the reservoir couplingsubstation 516 during addition of the reservoir substrate to thecartridge. Note that the carriage and components of the cartridgecoupled thereto are not illustrated in FIGS. 30-32 for clarity purposes.However, as illustrated in FIGS. 30-32, the reservoir couplingsubstation 516 may further comprise fingers 1024 a, 1024 b, which maycooperate with the head portion 1022 of the wrapping mechanism 1016 towrap the reservoir substrate about the components of the cartridge.Briefly, FIG. 30 illustrates movement of the head portion 1022 of thewrapping mechanism 1016 in a direction 1026 toward a position at whichthe cartridge would be located. As illustrated in FIG. 31, the fingers1024 a, 1024 b may then move in a direction 1028 toward a position atwhich the cartridge would be located. Further, as illustrated in FIG.32, the fingers 1024 a, 1024 b may move in directions 1030 a, 1030 btoward one another. As additionally illustrated in FIG. 32, the wrappingmechanism 1016 may move away from the fingers 1024 a, 1024 b at thistime.

The interaction of the wrapping mechanism 1016 and the fingers 1024 a,1024 b of the reservoir coupling substation 516 with the reservoirsubstrate 214 is schematically illustrated in FIG. 33. As illustrated,the reservoir substrate 214 may be held to the head portion 1022 of thewrapping mechanism 1016 by vacuum applied through apertures 1032extending therethrough. Accordingly, first and second ends 1034 a, 1034b of the reservoir substrate 214 may extend around opposing sides of theflow tube 210 and/or other components of the cartridge. In this regard,an inner surface of the head portion 1022 of the wrapping mechanism 1016may define a curved configuration that causes the ends 1034 a, 1034 b ofthe reservoir substrate 214 to extend around the flow tube 210 in amanner whereby they may be grasped by the fingers 1024 a, 1024 b. Moreparticularly, the inner surface of the head portion 1022 of the wrappingmechanism 1026 may define a partial elliptical configuration, such thatthe ends 1034 a, 1034 b of the reservoir substrate 214 remain in closeproximity to the flow tube 210 when wrapped thereabout and may begrasped by the fingers 1024 a, 1024 b.

The flow tube 210 may be asymmetrical. In this regard, the flow tube 210may define a shortened side 210 a and an elongated side 210 b (see,e.g., FIG. 1). As illustrated in FIG. 33, the wrapping mechanism 1016may be configured such that the head portion 1022 thereof is directedtoward the elongated side 210 b of the flow tube 210. In this regard,the elongated side 210 b of the flow tube 210 may contact the reservoirsubstrate 214 and facilitate wrapping the reservoir substrate thereaboutin an even manner, whereas wrapping the reservoir substrate about theshortened side 210 a of the flow tube may result in uneven wrapping ofthe reservoir substrate or damage to underlying components such as thecontrol component.

Note further that the heating terminals 234 a, 234 b may be orientedrelative to the wrapping mechanism 1016 such that when the reservoirsubstrate 214 is wrapped about the partially assembled cartridge, theliquid transport element 238 is forced into further engagement with theheating terminals. In this regard, as illustrated by arrows 1036 a, 1036b, the liquid transport element 238 may be pressed by the reservoirsubstrate 214 into inner corners defined by the heating elements 234 a,234 b. More particularly, as illustrated, the heating elements 234 a,234 b may include substantially perpendicularly extending walls definesan “L-shape,” and the liquid transport element 238 may be forced into aninner corner between the two walls. Accordingly, wrapping the reservoirsubstrate 214 about the partially assembled cartridge may assist inpositioning the liquid transport element 238 in a desired position(e.g., a position wherein the liquid transport element extendssubstantially parallel to a longitudinal length of the heating terminals234 a, 234 b).

The fingers 1024 a, 1024 b may be configured to engage the reservoirsubstrate 214 and further wrap the reservoir substrate about the flowtube 210 and/or the remainder of the partially assembled cartridge. Forexample, as illustrated in FIGS. 32 and 33, the fingers 1024 a, 1024 bmay be configured to move in directions 1030 a, 1030 b toward oneanother such that the reservoir substrate 214 is pinched around the flowtube 210 and/or other components of the partially assembled cartridge.In some embodiments the fingers 1024 a, 1024 b may be directed towardone another substantially simultaneously. For example, this may beemployed in embodiments of cartridges in which the ends 1034 a, 1034 bof reservoir substrate 214 form a butt-joint, or do not otherwiseoverlap. However, in embodiments in which the ends 1034 a, 1034 b of thereservoir substrate 214 overlap, one of the fingers 1024 a, 1024 b maymove before and/or faster than the other finger, such that one of theends may wrap around the flow tube 210 and then the other end of thereservoir substrate may wrap about that end.

After the reservoir substrate 214 is wrapped about the flow tube 210 andthe atomizer 212 and/or other components of the cartridge, the outerbody coupling substation 518 may couple the outer body to the base. Inthis regard, as illustrated in FIGS. 30-32, in some embodiments theouter body coupling substation 518 may include an outer body couplingtool 1102, which may be positioned proximate the fingers 1024 a, 1024 b.

Further, the outer body coupling substation 518 may include an outerbody supply mechanism 1104, as illustrated in FIG. 34. The outer bodysupply mechanism 1104 may include a pivoting prong 1106. The pivotingprong 1106 may be configured to receive an outer body 216 (see, e.g.,FIG. 1) directed thereto in an initial substantially horizontalconfiguration and then pivot, as indicated by arrow 1108, such that theouter body received thereon extends substantially vertically. Thereby,the outer body coupling tool 1102 may be directed over the outer body216 such that the outer body may be received therein.

The outer body coupling tool 1102 may comprise multiple sections (e.g.two or more sections) which cooperate to receive the outer body 216 byradially separating from one another. In this regard, FIG. 35illustrates a perspective view of a section 1102 a of the outer bodycoupling tool 1102. As illustrated, each section 1102 a may define a lip1110 configured to retain the outer body 216 in the outer body couplingtool 1102 when the sections of the outer body coupling tool are radiallycontracted toward one another. In this regard, the outer body couplingtool 1102 may include a body receiving portion 1113 defining an innerradius that is at least as large as an outer radius of the outer body216 and an inner radius of the lip 1110 may be less than the outerradius of the outer body.

Accordingly, as illustrated in FIG. 36, the outer body 216 may beretained in the outer body coupling tool 1102 by the lip 1110. Asfurther illustrated in FIG. 36, the outer body coupling tool 1102 mayfacilitate placement of the outer body 216 over the reservoir substrate214. In this regard, each section 1102 a the outer body coupling tool1002 may define a funnel portion 1112. The funnel portion 1112 may beconfigured to reduce an outer dimension of the reservoir substrate 214such that the outer dimension of the reservoir substrate is less than orequal to an internal dimension of the outer body 216 to facilitateinsertion of the reservoir substrate into the outer body. In thisregard, the reservoir substrate 214 may comprise a flexible, fabric-likematerial, which may stick out in certain directions, making it difficultto directly insert the reservoir substrate 214 into the outer body 216when the reservoir substrate is wrapped about the flow tube 210 and/orother components of the cartridge. Thus, the funnel portion 1112 maydefine a minimum inner radius that is less than or equal to the innerradius of the outer body. Accordingly, when the outer body coupling tool1102 presses down over the reservoir substrate 214, the reservoirsubstrate may be compacted by the funnel portion 1112 such that itslides relatively easily into the outer body 216.

As illustrated, in some embodiments one or both of the fingers 1024 a,1024 b may engage the reservoir substrate 214 such that the reservoirsubstrate remains at least partially wrapped about the atomizer whenbeginning to insert the reservoir substrate through the outer bodycoupling tool 1002 into the outer body 216. In this regard, thefinger(s) 1024 a, 1024 b may prevent the reservoir substrate 214 fromunwrapping as the outer body 216 is inserted over the reservoirsubstrate. However, the fingers 1024 a, 1024 b may release from thereservoir substrate 214 after the outer body 216 has received thereservoir substrate a predefined distance therein (e.g., when thereservoir substrate is halfway into the outer body), at which time riskof the reservoir substrate unwrapping is substantially reduced.

Note that in some embodiments multiple sets of fingers 1024 a, 1024 b,1024 a′, 1024 b′, 1024 a″, 1024 b″ may be employed to hold the reservoirsubstrate 214 in the wrapped configuration, as illustrated in FIG. 36A.Thus, the fingers 1024 a, 1024 b, 1024 a′, 1024 b′, 1024 a″, 1024 b″ maybe sequentially released as the reservoir substrate 214 is insertedthrough the outer body coupling tool 1002 into the outer body 216. Forexample, a first set of fingers 1024 a, 1024 b may be released, followedby a second set of fingers 1024 a′, 1024 b′, followed by a third set offingers 1024 a″, 1024 b″ as the reservoir substrate 214 is inserted intothe outer body 216. By employing multiple sets of fingers at differingpositions along a longitudinal length of the partially assembledcartridge, the reservoir substrate may more securely be retained in thewrapped configuration during insertion into the outer body, such thatissues with respect to the reservoir substrate moving from the wrappedconfiguration may be avoided.

Further, in some embodiments the outer body coupling tool 1102 may twistduring insertion of the reservoir substrate 214 through the outer bodycoupling tool into the outer body 216, as illustrated in FIGS. 36 and36A. In particular, the outer body coupling tool 1102 may twist about alongitudinal axis 1114 thereof. Accordingly, friction between the funnelportion 1112 of the outer body coupling tool 1102 and the reservoirsubstrate 214 may be reduced. In some embodiments the outer bodycoupling tool 1102 may twist in a single direction about thelongitudinal axis 1114. In another embodiment the outer body couplingtool 1102 may oscillate between rotating in first and second opposingdirections 1116 a, 1116 b during insertion, which may reduce the chancefor movement of the reservoir substrate 214 during insertion through theouter body coupling tool into the outer body 216. Note that in someembodiments the sections 1102 a of the outer body coupling tool 1102 mayclamp on the outer body 216 such that the outer body rotates with theouter body coupling tool. Thus, friction between the outer body 216 andthe reservoir substrate 214 may be reduced. Accordingly, twistingmovement of outer body 216 with respect to the reservoir substrate 214may further facilitate insertion of the reservoir substrate into theouter body.

Following insertion of the reservoir substrate 214 and the othercomponents of the cartridge into the outer body 216, the outer body maybe coupled to the base 204. In this regard, the outer body couplingsubstation 518 may further comprise a crimper 1118, as illustrated inFIG. 37. In some embodiments the crimper 1118 may comprise multiplesections 1118 a. For example, in the embodiment illustrated in FIG. 37,the crimper 1118 comprises four sections 1118 a, which may besubstantially identical. In this regard, use of a crimper comprisingfour or more sections may crimp the outer body more evenly than crimpersdefining fewer sections, such that leaks between the outer body and thebase may be avoided. However, in other embodiments, the number ofsections may vary. For example, two or more sections may be employed.

FIG. 38 illustrates one of the sections 1118 a of the crimper 1118. Asillustrated, each section 1118 a may include a lip 1120 configured tocrimp the outer body 216. FIG. 39 illustrates an enlarged view ofsection A from FIG. 38. As illustrated, in FIG. 39, an angled portion1122 may extend from the lip 1120 to an inner surface 1124 of thesection 1118 a of the crimper 1118. In some embodiments the angledportion 1122 of the sections 1118 a may define an angle 1126 withrespect to a longitudinal axis 1128 of the crimper 1118 along which thecrimper receives the outer body 216 from about 10 degrees to about 15degrees and preferably about 12 degrees. In this regard, the angledportion 1122 may provide for a smooth transition from a crimp formed inthe outer body 216 by the lip 1120 to the remainder of the outer body.Thereby, leaks between the outer body 216 and the base 204 may besubstantially avoided.

Accordingly, FIGS. 4-39 illustrate one embodiment of a cartridgeassembly subsystem 402. However, as may be understood, various otherembodiments of cartridge assembly subsystems may be employed to assemblecartridges in accordance with embodiments of the present disclosure. Inthis regard, FIG. 40 schematically illustrates a cartridge assemblysubsystem 402′ according to another embodiment of the presentdisclosure.

As illustrated, the cartridge assembly subsystem 402′ may include a baseload substation 1202, a terminal coupling substation 1204, a terminalsealing substation 1206, a control component coupling substation 1208, aflow tube coupling substation 1210, a heating element couplingsubstation 1212, a liquid transport element bending substation 1214, areservoir coupling substation 1216, and an outer body couplingsubstation 1218. Further, the controller 417 may be configured tocontrol one or more of the substations 1202-1218 of the cartridgeassembly subsystem 402′. Accordingly, the cartridge assembly subsystem402′ may be similar to the cartridge assembly subsystem 402 describedabove and illustrated in FIGS. 4-39. Thus, the description providedhereinafter relating to the cartridge assembly subsystem 402′ will focusprimarily on differences with respect to the previously describedcartridge assembly subsystem 402 for brevity purposes.

In this regard, the cartridge assembly subsystem 402 described abovegenerally assembled cartridges upwardly from a carriage 600 transportedbetween various subsystems. More particularly, the carriage 600 wouldgenerally pause at each substation, such that the base 204 was in astationary position with the components moved into contact therewithfrom above.

However, the cartridge assembly subsystem 402′ described hereinafterdiffers in that the base 204 is generally directed into contact withstationary components to form a cartridge. In particular, the base 204may be inverted and directed generally downwardly to engage thecomponents therewith to form the cartridge in some embodiments. FIG. 41illustrates an overhead view of one embodiment of the cartridge assemblysubsystem 402′. In this regard, robots (e.g., robotic arms) may beconfigured to hold the base 204 and direct the base into contact withthe components during assembly therewith to form cartridges.

For example, as illustrated in FIG. 41, a plurality of robots may beemployed to move the base 204 into engagement with various components toassemble the cartridge. The robots may interact with the components ofthe cartridge and each other to perform various assembly operations suchthat each robot may not be specifically associated with only one of thesubstations 1202-1218 illustrated in FIG. 40. However, as illustrated inFIG. 41, in one embodiment the cartridge assembly subsystem 402′ mayinclude a control component terminal robot 1302, a heating terminalrobot 1304, a robotic arm 1306, a control component and flow tube robot1308, a heating element robot 1310, a reservoir substrate robot 1312,and an outer body robot 1314.

As illustrated in FIG. 42, the base load substation 1202 may include abase supply 1402 configured to supply the base 204. In some embodimentsthe base supply 1402 may comprise a vibratory bowl feeder. Further, thebase supply 1402 may orient the bases 204 for grasping. In this regard,an attachment end 204 a of the base (see, FIG. 1) may be orientedupwardly by the base supply 1202.

As noted above, in some embodiments portions of the cartridge assemblysubsystem 402′ may be configured to grasp the base 204 such that thebase is inverted during assembly of the cartridge. Additionally oralternatively, portions of the cartridge assembly subsystem 402′ may beconfigured to grasp an internal surface 204 a′ of an attachment end 204a of the base 204 (see, FIG. 1) configured to engage a control body. Inorder to grasp the internal surface 204 a′ of an attachment end 204 a ofthe base 204, appropriate grippers may be employed.

In this regard, FIG. 43 illustrates a base gripper 1500 that may beemployed by robots of the cartridge assembly subsystem 402′. Asillustrated, the base gripper 1500 may define multiple sections 1502.The sections 1502 may be configured to contract (e.g., move radiallyinward toward one another) during insertion into the attachment end 204a of the base 204, and expand (e.g., move radially move outwardly awayfrom one another) after inserted into the attachment end of the base. Aplurality of protrusions 1504 or other features (e.g., recesses) on anouter surface 1506 of each of the sections 1502 may assist in grippingthe base 204. For example, the protrusions 1504 may be configured toengage recesses defined in the internal surface 204 a′ of the attachmentend 204 a of the base 204. In this regard, the outer surfaces 1506 ofthe sections 1502 of the base gripper 1500 may be configured tocorrespond to the shape of the internal surface 204 a′ of the attachmentend 204 a of the base 204. Accordingly, the base gripper 1500 maysecurely, and releasably, engage the base 204.

The terminal coupling substation 1204 may comprise the control componentterminal robot 1302. As illustrated in FIG. 42, the control componentterminal robot 1302 may include the base gripper 1500. Thereby, thecontrol component terminal robot 1302 may grasp a base 204 supplied bythe base supply 1402. Accordingly, the control component terminal robot1302 may couple the control component terminal to the base.

In this regard, as illustrated in FIG. 44, the terminal couplingsubstation 1204 may further comprise a die 1600 configured to preparethe control component terminal 206 for attachment to the base 204. Forexample, the control component terminal 206 may be cut from asubstantially continuous control component terminal input 1602. In thisregard, a cutter 1604 may cut the control component terminal 206 fromthe substantially continuous control component terminal input 1602.

FIG. 44A illustrates an enlarged view of the die 1600. As illustrated inFIG. 44A, the die 1600 may further comprise first and second pressurepads 1606 a, 1606 b, which may be positioned on opposing sides of thecutter 1604. The pressure pads 1606 a, 1606 b may extend into contactwith, and press against the substantially continuous control componentterminal input 1602 as the cutter 1604 cuts a control component terminal206 therefrom. More particularly, the first pressure pad 1606 a maypress against a first control component terminal 206 a, which is cutfrom the substantially continuous control component terminal input 1602by the cutter 1604, and the second pressure pad 1606 b may press againsta second control component terminal 206 b which is next in line to beseparated from the substantially continuous control component terminalinput. Accordingly, the first control component terminal 206 a may beheld in place while being cut from the substantially continuous controlcomponent terminal input 1602, and the second control component terminal206 b, which then becomes the first control component terminal at theend of the substantially continuous control component terminal input,are both held in place.

Following singulation, the first control component terminal 206 a may beheld in a stationary position to facilitate coupling with the base 204.More particularly, the first control component terminal 206 a may bepinched between backing member 1608 and an opposing pressure pad 1610.In this regard, one or both of the opposing pressure pad 1610 and thebacking member 1608 may move toward the first control component terminal206 a such that the first control component terminal is pinchedtherebetween. As illustrated, the opposing pressure pad 1610 and thebacking member 1608 may define a contour that matches each of thecontrol component terminals 206, such that the control componentterminal may be securely held in place without affecting the shape ofthe control component terminal. Thereby, the base 204 may be directedinto contact with the singulated control component terminal 206. Forexample, the control component terminal robot 1302 may direct the base204 downwardly into contact with the stationary control componentterminal 206, such that the control component terminal engages the base.

The terminal coupling substation 1204 may further comprise the heatingterminal robot 1304. In this regard, after the control componentterminal robot 1302 couples the control component terminal 206 to thebase 204, the control component terminal robot may transfer the base tothe heating terminal robot 1304. In some embodiments a transfer membermay facilitate transfer of the base 204 from the control component robot1302 to the heating terminal robot 1304.

As illustrated in FIG. 45, in one embodiment the transfer member 1700Acomprises a wheel 1702 which rotates to deliver the base 204 from thecontrol component terminal robot 1302 to the heating terminal robot1304. The transfer member 1700A may further comprise one or morefixtures 1704 coupled to the wheel 1702. Accordingly, the controlcomponent terminal robot 1302 may deposit the base 204 in one of thefixtures 1704, the transfer member 1700A may rotate, and the heatingterminal robot 1304 may grasp the base in the fixture and remove thebase therefrom.

In this regard, by depositing the base 204 in the fixture 1704, the basemay be positioned such that the heating terminal robot 1304 may graspthe base in substantially the same manner as that employed by thecontrol component terminal robot 1302 to grasp the base. For example,the heating terminal robot 1304 may include a base gripper, such as theabove-described base gripper 1500. Thereby, the base 204 may be directedby the heating terminal robot 1304 into contact with the first andsecond heating terminals 234 a, 234 b (see, e.g., FIG. 1). Moreparticularly, as illustrated in FIG. 45, first and second dies 1612 a,1612 b may cut the first and second heating terminals 234 a, 234 b fromfirst and second substantially continuous control component terminalinputs, which may be substantially similar to the substantiallycontinuous first heating terminal input 700 described above. Thereby,after engaging the first and second heating terminals 234 a, 234 b withthe base 204, the heating terminal robot 1304 may deposit the base in asecond transfer member 1700B (see, e.g., FIG. 41), which may besubstantially similar to the transfer member 1700A described above.

The base 204 may then be engaged by the robotic arm 1306. The roboticarm 1306 may deposit the base 204 on a third transfer member 1700C,which may be substantially similar to the previously-described transfermembers 1700A, 1700B. Further, in some embodiments the robotic arm 1306may comprise part of the terminal sealing substation 1206, inembodiments in which sealing of the heating terminals 234 a, 234 b withrespect to the base 204 is employed. In this regard, the terminalsealing substation 1206 may function in substantially the same manner asthe terminal sealing substation 506 described above, wherein the roboticarm 1306 functions in substantially the same manner as the robotic arm808 (see, e.g., FIG. 10). In some embodiments, one or both of therobotic arms 808, 1306 may employ the above-described base gripper 1500to engage the base 204 during the sealing process.

Regardless of whether or not the terminal sealing substation 1206 isemployed, the robotic arm 1306 may deposit the base 204 on the thirdtransfer member 1700C. Thereafter, the base 204 may be directed to thecontrol component coupling substation 1208 and the flow tube couplingsubstation 1210. In the illustrated embodiment, both the controlcomponent coupling substation 1208 and the flow tube coupling substation1210 include and employ the control component and flow tube robot 1308.

In this regard, as illustrated in FIG. 46 the control component and flowtube robot 1308 may be configured to engage the base 204 at the thirdtransfer member 1700C. For example, as illustrated, the controlcomponent and flow tube robot 1308 may include a gripper such as thebase gripper 1500. Thereby, the control component and flow tube robot1308 may transfer the base 204 to the control component couplingsubstation 1208.

Further, the control coupling substation 1208 may include a controlcomponent supply 1802 (see, FIG. 41) configured to supply the electroniccontrol component 208. In some embodiments the control component supply1802 may comprise a vibratory bowl feeder. Further, the controlcomponent supply 1802 may orient the electronic control component 208 ina desired manner. For example as illustrated in FIG. 47, each of theelectronic control components 208 may be oriented such that a chip 208′(e.g., a memory chip) or other portion of the electronic controlcomponent is oriented upwardly. In this regard, the first and secondmajor sides of the electronic control component 208 may be asymmetrical,which may facilitate orientation by the control component supply 1802such that the chip 208′ extends upwardly.

As further illustrated in FIG. 47, the electronic control component 208may define first and second opposing longitudinal ends 208A, 208B. Aconnector at the first end 208A of the electronic control component 208may be configured to engage the control component terminal 206. In thisregard, as illustrated in FIG. 46, an imaging device 1804 (e.g., acamera) may be configured to determine whether the first end 208A is atthe front or rear of the electronic control component 208 in terms ofthe direction that the electronic control components are supplied by thecontrol component supply 1802.

Accordingly, as illustrated in FIG. 47, based on the determinedorientation of the electronic control component 208, a control componentgripper 1806 may grasp the second end 208B of the electronic controlcomponent. In this regard, the control component gripper 1806 mayinclude first and second fingers 1808A, 1808B configured to pinch thesecond end 208B of the control component 208 therebetween. Asillustrated, the first and second fingers 1808A, 1808B may be relativelynarrow. In this regard, the control component supply 1802 may direct thecontrol components 208 to a support member 1810. The support member 1810may define first and second slots 1812A, 1812B configured torespectively align with one of the first and second ends 208A, 208B ofan electronic control component 208 when the electronic controlcomponent is received on the support member. Accordingly, the grippers1808A, 1808B may extend into one of the slots 1812A, 1812B in thesupport member 1810 and grasp the second end 208B of the controlcomponent 208.

Thereby, as further illustrated in FIG. 47, the control componentgripper 1806 may rotate the electronic control component 208 such thatthe first end 208A thereof points upwardly. Accordingly, the controlcomponent and flow tube robot 1308 may direct the base 204 downwardlysuch that the first send 208A of the electronic control component 208engages the control component terminal 206. In some embodiments theconnector (e.g., a contact patch) at the first end 208A of theelectronic control component 208 may be located on only one of the majorsides of the electronic control component and the control componentterminal 206 may be asymmetrical and configured to engage only thatparticular side. Accordingly, the control component and flow tube robot1308 may rotate the base 204 such that a desired rotational alignment ofthe electronic control component 208 and the control component terminal206 is achieved when the base 204 is directed downwardly toward theelectronic control component.

After coupling of the electronic control component 208 to the controlcomponent terminal 206, the base 204 may be directed by the controlcomponent and flow tube robot 1308 to the flow tube coupling substation1210. As illustrated in FIG. 41, the flow tube coupling substation 1210may include a flow tube supply 1902 configured to supply the flow tube210. In some embodiments the flow tube supply 1902 may comprise avibratory bowl feeder. Further, the flow tube supply 1902 may orient theflow tube 210 in a desired manner.

The flow tube coupling substation 1210 may further comprise a base 1904,as illustrated in FIGS. 46 and 48. The base 1904 may define an upwardlyextending protrusion configured to mate with an inner portion of theflow tube 210 to support the flow tube thereon. Thereby, the controlcomponent and flow tube robot 1308 may direct the base 204 downwardlytoward the flow tube 210. Accordingly, the flow tube 210 may be receivedbetween the heating terminals 234 a, 234 b and engage the controlcomponent 208. As illustrated in FIG. 48, a flow tube gripper 1906 maygrasp the partially assembled cartridge. More particularly, the flowtube gripper 1906 may include a pair of arms 1908A, 1908B each includingan extension 1910 configured to press the heating terminals 234 a, 234 bagainst the flow tube 210. Thus, the flow tube gripper 1906 mayindirectly hold the flow tube 210 in place by pressing the heatingterminals 234 a, 234 b against the flow tube. By grasping the partiallyassembled cartridge in this manner, the base gripper 1500 of the controlcomponent and flow tube robot 1308 may release and retract from the base204 while the partially assembled cartridge is securely held in place.

Thereafter, the heating element robot 1310 may engage the partiallyassembled cartridge. In this regard, as illustrated in FIG. 49, theheating element robot 1310 may include a terminal gripper 2002. Asillustrated, the terminal gripper 2002 may include first and second arms2004A, 2004B. The first arm 2004A of the terminal gripper 2002 mayinclude a first pair of prongs 2006A and the second arm 2004B of theterminal gripper may include a second pair of prongs 2006B.

In this regard, as illustrated in FIG. 50, the terminal gripper 2002 maybe configured to engage the heating terminals 234 a, 234 b. However, asnoted above, the partially assembled cartridge may be held in place bythe flow tube gripper 1906. Thus, the terminal gripper 2002 may beconfigured to avoid contacting the flow tube gripper 1906. For example,as illustrated, the terminal gripper 2002 may be configured to extend atleast partially between the arms 1908 a, 1908 b of the flow tube gripper1906. In this regard, the heating element robot 1310 may rotate suchthat the first and second arms 2004A, 2004B of the terminal gripper 2002extend perpendicularly to the first and second arms 1908A, 1908B of theflow tube gripper 1906.

Accordingly, as illustrated in FIG. 51, the terminal gripper 2002 maygrip the partially assembled cartridge. In particular, the first pair ofprongs 2006A and the second pair of prongs 2006B may pinch the heatingterminals 234 a, 234 b therebetween. More particularly, one of the firstpair of prongs 2006A and one of the second pair of prongs 2006B maypress against opposing sides of the first heating terminal 234 a suchthat the first heating terminal is held therebetween. Similarly, one ofthe first pair of prongs 2006A and one of the second pair of prongs2006B may press against opposing sides of the second heating terminal234 b such that the second heating terminal is held therebetween. Asillustrated, the prongs 2006A, 2006B may engage the heating terminals234 a, 234 b such that the heating terminal tabs 952 a, 952 b areexposed. For example, when the base 204 is oriented such that theheating terminals 234 a, 234 b extend downwardly therefrom, the prongs2006A, 2006B may engage the heating terminals slightly above the heatingterminal tabs 952 a, 952 b.

Further, by grasping the heating terminals 234 a, 234 b in theabove-described manner, the heating terminal tabs 952 a, 952 b may beconfigured in a desired position for attachment of the heating elementthereto. In this regard, as described above, the flow tube gripper 1906may press the heating terminals 234 a, 234 b against the flow tube 210.Thereby, when the terminal gripper 2002 grasps the heating terminals 234a, 234 b, the heating terminal tabs 952 a, 952 b may define a desiredseparation therebetween, as defined by the width of the flow tube 210.Further, when the terminal gripper 2002 presses against opposing sidesof each of the heating terminal tabs 952 a, 952 b with the prongs 2006A,2006B, the heating terminal tabs may be aligned.

The heating element coupling substation 1212 may include theabove-described heating element robot 1310. Additionally, as illustratedin FIG. 52, the heating element coupling substation 1212 may include apreparing portion 2008 and a welding portion 2010. The preparing portion2008 and the welding portion 2010 may function in substantially the samemanner as the preparing portion 902 and the welding portion 904described above (see, e.g., FIG. 12). In this regard, as illustrated inFIG. 53, in some embodiments the heating element may be supplied from asubstantially continuous heating element input 2012. The substantiallycontinuous heating element input 2012 may comprise a plurality of theheating elements 240 wound about the liquid transport element 238 asdescribed, for example, in U.S. patent application Ser. No. 13/827,994,filed Mar. 14, 2013 and Ser. No. 13/708,381, filed Dec. 7, 2012, whichare incorporated herein by reference in their entireties.

As illustrated, the substantially continuous heating element input 2012may be supplied from a spool 2014 in some embodiments. The spool 2014may passively rotate as the substantially continuous heating elementinput 2014 is pulled therefrom. Alternatively, the spool 2014 may beactively driven (e.g., by a motor) such that the spool rotates as thesubstantially continuous heating element input 2012 is pulled therefrom.By either actively rotating the spool 2014 or passively allowing thespool to substantially freely rotate as the substantially continuousheating element input 2012 is pulled therefrom, tension in thesubstantially continuous heating element input may be controlled toavoid damage thereto.

In one embodiment the position of the substantially continuous heatingelement input 2012 may be monitored such that the spool 2014 mayactively supply the substantially continuous heating element input tomaintain a desired amount of slack therein. For example, as illustratedin FIG. 53, in one embodiment an upper sensor 2016 a and a lower sensor2016 b may be provided, with the substantially continuous heatingelement input 2012 draped off the spool 2014 such that it extendsbetween the sensors 2016 a, 2016 b. In one embodiment the sensors 2016a, 2016 b may each include a light emitter and a light detector, whichmay detect when an object blocks the light from reaching the lightdetector. Accordingly, the spool 2014 may be actively driven based ondetection of the substantially continuous heating element input 2012.For example, if the upper sensor 2016 a detects a blockage of lightcaused by the substantially continuous heating element input 2012, thespool 2014 may be directed to rotate or rotate more quickly. Conversely,if the lower sensor 2016 b detects a blockage of the light caused by thesubstantially continuous heating element input 2012, the spool 2014 maybe directed to rotate more slowly or stop. Accordingly, tension in thesubstantially continuous heating element input 2012 may be controlled.For example, the controller 417 may be in communication with the sensors2016 a, 2016 b and configured to direct the spool 2014 to rotate asdescribed above.

As noted above, the preparing portion 2008 of the heating elementcoupling substation 1212 may be substantially similar to the preparingportion 902 described above. In this regard, the preparing portion 2008may be configured to prepare an individual heating element 240 coupledto the liquid transport element 238 for welding. Accordingly, thepreparing portion 2008 will not be described in detail.

Briefly, however, as illustrated in FIG. 52, the preparing portion 2008may include a dispenser 2018, a cutter 2020, and an imaging device 2022(e.g., a camera). Thereby, the dispenser 2018 may pull on thesubstantially continuous heating element input 2012 until a controllerdetermines that a desired length of the substantially continuous heatingelement input 2012 has been dispensed, based on images captured by thecamera 2022. In this regard, the controller may determine the center ofthe heating element in the same manner as described above. Thereby, atransport apparatus 2024 (see, FIG. 54) may grasp the substantiallycontinuous heating element input 2012 such that the heating element 240is centered between first and second arms 2026 a, 2026 b thereof.

The cutter 2020 may cut the substantially continuous heating elementinput 2012 to singulate an individual heating element 240 and liquidtransport element 238. A new end of the substantially continuous heatingelement input 2012 may be supported by a tube 2028, as illustrated inFIG. 52, such that the end is ready for grasping by the dispenser 2018in order to repeat the above-described process.

As illustrated in FIG. 54, the welding portion 2010 may comprise ahousing 2030. The transport apparatus 2024 may transport the singulatedheating element 240 and liquid transport element 238 into a chamber 2032defined by the housing 2030. Further, as illustrated in FIG. 55, theheating element robot 1310 may come into contact with the housing 2030.More particularly, the heating element robot 1310 may direct at leastthe heating terminal tabs 952 a, 954 b of the heating terminals 234 a,234 b into the chamber 2032 defined by the housing.

Accordingly as illustrated in FIG. 52, an imaging device 2034 (e.g., acamera) may captures images of the heating element 240 and the heatingterminal tabs 952 a, 954 b of the heating terminals 234 a, 234 b.Thereby, a controller may direct the transfer apparatus 2024 and theheating element robot 1030 to respectively align a center of the heatingelement 240 and a center of the heating terminals 234 a, 234 b with acenter of the imaging device 2034. Thus, the heating element robot 1030may press the heating terminal tabs 952 a, 952 b against the contactportions 926, 928 of the heating element 240 (see, e.g., FIG. 23). Anupward-looking imaging device may be employed to determine thehorizontal position of the heating terminals 234 a, 234 b relative tothe heating element 240 such that contact therebetween may beestablished. A laser 2036 may direct laser beams against the backs ofthe heating terminal tabs 952 a, 952 b such that the heating element 240is welding to the heating terminals 234 a, 234 b in substantially thesame manner as described above. In this regard, a gas dispenser (e.g., afitting coupled to a bottom of the housing 2030) may be configured todispense an inert gas (e.g., argon) into the chamber 2032 to improve theresultant weld (e.g., by preventing oxidation thereof).

Further, the chamber 2032 defined by the housing 2030 may besubstantially sealed before welding the heating element 240 to the firstheating terminal 234 a and the second heating terminal 234 b. In thisregard, as illustrated in FIG. 55, the heating element robot 1310 mayinclude a sealing member 2038 configured to engage the housing 2030. Inthis regard, when the heating terminals 234 a, 234 b are inserted intothe housing 2030, the sealing member 2038 of the heating element robot1310 may seal thereagainst. Similarly, a second sealing member 2040 mayseal the transport apparatus 2024 to the housing 2030 when the transportapparatus directs a heating element 240 into the chamber 2032 and athird sealing member 2042 may create a seal between the camera 2034and/or the laser 2036 and the housing 2030. Accordingly, bysubstantially sealing closed the chamber 2032 defined by the housing,issues with respect to the laser beam exiting the chamber may beaverted. Additionally, use of the substantially sealed chamber 2032 mayfacilitate usage of the inert gas by at least partially retaining theinert gas in the chamber 2032. Further, as noted above, variousalternate attachment methods, including various other types of welding,may be employed to couple the heating element to the heating terminals.

Following welding, the partially assembled cartridge may be transportedto the liquid transport element bending substation 1214. In this regard,the heating element robot 1310 may transport the partially assembledcartridge thereto in some embodiments. FIG. 56 illustrates an exampleembodiment of the liquid transport element bending substation 1214. Asillustrated, the liquid transport element bending substation 1214 mayinclude first and second upright members 2102 a, 2102 b. Upper channels2104 a, 2104 b and side channels 2106 a, 2106 b may be defined in theupright members 2102 a, 2102 b.

The heating element robot 1310 may be configured to direct the partiallyassembled cartridge between the upright members 2102 a, 2102 b of theliquid transport element bending substation 1214. More particularly, theheating element robot 1310 may orient the partially assembled cartridgesuch that the liquid transport element 238 enters the upper channels2104 a, 2104 b. As the partially assembled cartridge is inserted downbetween the upright members 2102 a, 2102 b, the liquid transport element238 may begin to bend and enter the side channels 2106 a, 2106 b definedat inner surfaces of the upright members. Further, as illustrated inFIG. 57, the upright members 2102 a, 2102 b may pinch toward one anothersuch that the liquid transport element 238 bends more and comes intocontact with the heating terminals 234 a, 234 b.

Once the liquid transport element 238 is bent, the reservoir substraterobot 1312 may grasp the partially assembled cartridge. As illustratedin FIG. 58, the reservoir substrate robot 1312 may include a base andwick gripper 2202. The base and wick gripper 2202 may include first andsecond portions 2204 a, 2204 b. Each of the portions 2204 a, 2204 b mayinclude a base gripper section 2206. For example, in the illustratedembodiment the base gripper sections 2206 comprise v-notches thatcooperate to center the base 204 therein. Further, each of the portions2204 a, 2204 b may include a wick gripper section 2208 configured toengage the liquid transport element 238.

In this regard, FIG. 59 illustrates the base and wick gripper 2202engaged with the partially assembled cartridge. As illustrated, the base204 may be received between the base gripper sections 2206. Further, thewick gripper section 2208 may pinch against ends of the liquid transportelement 238. Accordingly, the base and wick gripper 2202 may retain theliquid transport element 238 in the bent configuration.

The reservoir substrate robot 1312 may thus transport the partiallyassembled cartridge, with the liquid transport element 238 in the bentconfiguration, to the reservoir coupling substation 1216, where thereservoir substrate 214 is coupled thereto. Accordingly, the reservoirsubstrate 214 may be prepared for attachment to the partially assembledcartridge. In this regard, as illustrated in FIG. 60, a substantiallycontinuous reservoir substrate input 2302 may be supplied from a spool2304 in some embodiments. The spool 2304 may passively rotate as thesubstantially continuous reservoir substrate input 2302 is pulledtherefrom. Alternatively, the spool 2304 may be actively driven (e.g.,by a motor) such that the spool rotates as the substantially continuousreservoir substrate input 2302 is pulled therefrom. By either activelyrotating the spool 2304 or passively allowing the spool to substantiallyfreely rotate as the substantially continuous reservoir substrate input2302 is pulled therefrom, tension in the substantially continuousreservoir substrate input may be controlled to avoid damage thereto.

In one embodiment the position of the substantially continuous reservoirsubstrate input 2302 may be monitored such that the spool 2304 mayactively supply the substantially continuous reservoir substrate inputto maintain a desired amount of slack therein. For example, asillustrated in FIG. 60, in one embodiment an upper sensor 2306 a and alower sensor 2306 b may be provided, with the substantially continuousreservoir substrate input 2302 draped off the spool 2304 such that itextends between the sensors 2306 a, 2306 b. In one embodiment thesensors 2306 a, 2306 b may each include a light emitter and a lightdetector, which may be positioned at opposing ends of a trough 2308, andwhich may detect when an object blocks the light from reaching the lightdetector. Accordingly, the spool 2304 may be actively driven based ondetection of the substantially continuous reservoir substrate input2302. For example, if the upper sensor 2306 a detects a blockage oflight caused by the substantially continuous reservoir substrate input2302, the spool 2304 may be directed to rotate or rotate more quickly.Conversely, if the lower sensor 2306 b detects a blockage of the lightcaused by the substantially continuous reservoir substrate input 2302,the spool 2304 may be directed to stop or rotate more slowly.Accordingly, tension in the substantially continuous reservoir substrateinput 2302 may be controlled. For example, the controller 417 may be incommunication with the sensors 2306 a, 2306 bb and configured to directthe spool 2304 to rotate as described above.

The substantially continuous reservoir substrate input 2302 may besupplied from the spool 2304 to a singulation unit 2310. As illustratedin FIG. 61, the singulation unit 2310 may comprise a rotary wheel 2312defining a plurality of apertures 2314 at an outer surface thereof. Theapertures 2314 may be configured to apply vacuum to the substantiallycontinuous reservoir substrate input 2302 such that the substantiallycontinuous reservoir substrate input is retained thereon. Further, thesingulation unit 2310 may include a cutter 2316, as illustrated in FIG.62. The cutter 2316 may be configured to cut the substantiallycontinuous reservoir substrate input 2302 at predetermined intervals inorder to provide individual reservoir substrates 214. For example, aportion of the cutter 2316 may extend through cutouts 2317 defined inthe rotary wheel 2312 in order to cut the reservoir substrate withoutdamaging the rotary wheel. Thus, for example, the rotary wheel 2312 mayrotate in stepped increments corresponding to a desired length of theindividual reservoir substrates and corresponding to a distance betweencenters of the cutouts 2317. As illustrated in FIG. 61, after being cutfrom the substantially continuous reservoir substrate input 2302, thesingulated reservoir substrate 214 may be retained on the rotary wheel2312 by vacuum applied through the apertures 2314. However, the rotarywheel 2312 may be configured to transfer the reservoir substrate 214 toa wrapping mechanism 2318.

In this regard, as illustrated in FIG. 63, the wrapping mechanism 2318may include a moveable slide 2320 configured to move on a track 2322.The moveable slide 2320 may comprise a head portion 2324 with one ormore apertures 2326 defined therein. Thereby, the moveable slide 2320may move along the track 2322 such that the head portion 2324 comes intoproximity to the rotary wheel 2312. Thus, a reservoir substrate 214 maybe transferred from the rotary wheel 2312 to the head portion 2324 ofthe moveable slide 2320. For example, vacuum may be applied to theapertures 2326 in the head portion 2324. Thereby, when vacuum isrelieved from the apertures 2314 in the rotary wheel 2312 holding thereservoir substrate 214 and/or positive pressure is applied through theapertures in the rotary wheel, the reservoir substrate may betransferred to the head portion 2324 of the moveable slide 2320. In thisregard, the rotary wheel 2312 may be configured such that vacuum ceasesor positive pressure is applied to the apertures 2314 as the aperturesreach a specified angular position corresponding to a position at whichthe head portion 2324 of the moveable slide 2320 comes into proximitytherewith.

After transfer of a reservoir substrate 214 to the head portion 2324 ofthe moveable slide 2320, the moveable slide may begin moving back to aninitial starting position. The reservoir substrate robot 1312 may bringthe partially assembled cartridge into contact with the reservoirsubstrate 214 held by the head portion 2324 of the moveable slide 2320.Then the reservoir substrate robot 1312 and the moveable slide 2320 maymove in a synchronized manner in the same direction until the moveableportion reaches the position illustrated in FIG. 63. At this point,first and second arms 2328 a, 2328 b of a wrapping member 2330 may pinchtogether towards one another, which may cause the reservoir substrate214 to wrap around the partially assembled cartridge. The arms 2328 a,2328 b may move at the same time (e.g., to create a butt joint at theends of the reservoir substrate 214) or sequentially one after the other(e.g., to cause one end of the reservoir substrate to wrap around theother end). In this regard, the arms 2328 a, 2328 b may function insubstantially the same manner as the arms 1024 a, 1024 b described aboveand illustrated in FIG. 33.

Following wrapping of the reservoir substrate 214, the partiallyassembled cartridge may be directed to the outer body couplingsubstation 1218 by the outer body robot 1314. As illustrated in FIG. 64,in addition to the outer body robot 1314, the outer body couplingsubstation 1218 may include an outer body supply 2402 configured tosupply the outer body 216 204. In some embodiments the outer body supply2402 may comprise a vibratory bowl feeder, as illustrated in FIG. 41.

The outer body supply 2402 may supply the outer bodies 216 to a transfermember 2404. The transfer member 2404 may be configured to grasp anindividual outer body 216 and position the outer body for coupling tothe partially assembled cartridge. In this regard, as illustrated inFIG. 65, the outer body coupling substation 1218 may include an outerbody coupling tool 2406 configured to facilitate insertion of thereservoir substrate 214 into the outer body 216 and a crimper 2408configured to crimp the outer body to the base 204 after the outer bodyextends over the reservoir substrate and engages the base. A chamber2410 defined in the crimper 2408 may be configured to receive the outerbody 216 such that the partially assembled cartridge may be insertedtherein and then the outer body may be crimped to the base 204.

In order to deposit the outer body 216 in the chamber 2410, asillustrated in FIG. 66, the transfer member 2404 may include an outerbody gripper 2412 and a rotary arm 2414. Thus, the outer body gripper2412 may grasp an outer body 216 supplied by the outer body supply 2402.The outer body 216 may be supplied in a substantially horizontalconfiguration in some embodiments. Thereby, the rotary arm 2414 mayrotate such that the outer body 216 is substantially vertical andpositioned over the outer body coupling tool 2406 and the crimper 2408.The outer body gripper 2412 may release the outer body 216 such that itfalls though the outer body coupling tool 2406 into the chamber 2410defined by the crimper 2408.

In this regard, the outer body coupling tool 2406 may comprise aplurality of sections. For example, in the illustrated embodiment theouter body coupling tool 2406 comprises first and second sections 2416a, 2416 b. The sections 2416 a, 2416 b of the outer body coupling tool2406 may be moveable between an expanded configuration (see, e.g., FIGS.64 and 65) in which the sections are radially separated from oneanother, and a contracted configuration (see, FIG. 66), in which thesections are in contact with one another. Each section 2416 a, 2416 bthe outer body coupling tool 2406 may define a funnel portion 2418. Thefunnel portions 2418 may cooperate to define a funnel, as illustrated inFIG. 66, when the sections 2416 a, 2416 b are in the closedconfiguration. Accordingly, when the partially assembled cartridge isdirected into contact therewith, the outer body coupling tool 2406 mayreduce an outer dimension of the reservoir substrate 214 such that theouter dimension of the reservoir substrate is less than or equal to aninternal dimension of the outer body 216 to facilitate insertion of thereservoir substrate into the outer body. In this regard, the reservoirsubstrate 214 may comprise a flexible, fabric-like material, which maystick out in certain directions, making it difficult to directly insertthe reservoir substrate 214 into the outer body 216 when the reservoirsubstrate is wrapped about the flow tube 210 and/or other components ofthe cartridge. Thus, the funnel portions 2418 may define a funnel havinga minimum inner radius that is less than or equal to the inner radius ofthe outer body 216. Accordingly, when the outer body robot 1314 pressesthe partially assembled cartridge down through the outer body couplingtool 2406, the reservoir substrate 214 may be compacted by the funnelportions 2418 such that it slides relatively easily into the outer body216.

The outer body robot 1314 may include a gripper configured to facilitatethe above-described insertion of the partially assembled cartridgethrough the outer body coupling tool 2406 into the outer body 216. Inthis regard, FIG. 67 illustrates an exploded view of a reservoir gripper2420 and FIGS. 68 and 69 illustrates the gripper in an assembledconfiguration according to an example embodiment of the presentdisclosure. As illustrated, the reservoir gripper 2420 may include firstand second body portions 2422 a, 2422 b. The first and second bodyportions 2422 a, 2422 b may be configured to releasably clamp the base204 therebetween in order to hold the partially assembled cartridge.

Further, the reservoir substrate gripper 2420 may include a finger 2424configured to retain the reservoir substrate 214 in the wrappedconfiguration. Note that the reservoir substrate is not illustrated inFIGS. 67 and 68 for clarity purposes. The finger 2424 may be moveablycoupled with respect to the first body portion 2422 a of the reservoirsubstrate gripper 2420. The reservoir substrate gripper 2420 may beprovided with various features configured to facilitate movement of thefinger 2424 in the manner described below. However, in the illustratedembodiment the first body portion 2422 a of the reservoir substrategripper 2420 includes a channel 2426. The channel 2426 may be configuredto receive a protrusion or pin 2428 at an upper portion of the finger2424. The channel 2426 may be substantially straight in someembodiments. Further, the finger 2424 may comprise an elongated aperture2430 configured to receive a protrusion or pin 2432 coupled to the firstbody portion 2422 a. As illustrated, in some embodiments the elongatedaperture 2430 may generally define a path that extends upward and awayfrom a tip 2434 of the finger 2424.

The finger 2424 may be configured to retain the reservoir substrate 214in the wrapped configuration. In this regard, the tip 2434 of the finger2424 may be configured to press against the wrapped reservoir substrate214 while the outer body robot 1314 transports the partially assembledcartridge to the outer body coupling substation 1218. In this regard, asillustrated in FIG. 63, the arms 2328 a, 2328 b of the wrappingmechanism 2318 may each include upper and lower protrusions 2334 a, 2334b, which may assist in the above-described wrapping operations. Further,the protrusions 2334 a, 2334 b from one arm 2328 a may contact theprotrusions 2334 a, 2334 b on the opposing arm 2334 b when the arms aremoved toward one another such that a gap exists between the arms whenthe reservoir substrate is in the wrapped configuration.

Thereby, while the arms 2328 a, 2328 b hold the reservoir substrate inthe wrapped configuration, the outer body robot 1314 may engage thepartially assembled cartridge with the reservoir substrate gripper 2420.More particularly, the first and second body portions 2422 a, 2422 b mayengage the base 204 of the partially assembled cartridge. Further, thetip 2434 of the finger 2424 may extend between or below the protrusions2334 a, 2334 b to engage the reservoir substrate proximate a location atwhich the ends thereof overlap or meet at a joint. Accordingly, when thearms 2328 a, 2328 b of the wrapping mechanism 2318 retract, thereservoir substrate gripper 2420 may retain the reservoir substrate 214in the wrapped configuration by pressing against the reservoirsubstrate.

Accordingly, the partially assembled cartridge may include the reservoirsubstrate 214 wrapped thereabout when insertion through the outer bodycoupling tool 2406 into the outer body 216 begins. However, the finger2424 may be configured to release from the reservoir substrate 214during insertion of the partially assembled cartridge into the outerbody 216. In this regard, as the outer body robot 1314 inserts thepartially assembled cartridge through the outer body coupling tool 2406,the finger 2424 of the reservoir substrate gripper 2420 may contact theouter body coupling tool. Accordingly, the first body portion 2422 a maycontinue moving toward the outer body coupling tool 2406 while thefinger 2424 remains in contact with the outer body coupling tool.Accordingly, the finger 2424 may move along a path relative to the firstbody portion 2422 a defined by the interaction between the channel 2426and the pin 2428 and between the elongated aperture 2430 and the pin2432. Accordingly, the upper portion of the finger 2424 may remainsubstantially stationary as a result of the channel 2426 beingsubstantially straight. However, a lower portion of the finger 2424 maybe directed outward, away from the reservoir substrate 214 and theremainder of the partially assembled cartridge as a result of theelongated aperture 2430 defining a path that extends upward and awayfrom the tip 2434 of the finger. Accordingly, the tip 2434 of the finger2424 may deflect away from and release the reservoir substrate 214 asthe outer body robot 1314 inserts the partially assembled cartridgethrough the outer body coupling tool 2406.

Note that the particular embodiment of the reservoir substrate gripper2420 may vary while still operating in a manner similar to thatdescribed above. For example, FIG. 69 illustrates an alternateembodiment of a reservoir substrate gripper 2420′. The reservoirsubstrate gripper 2420′ may be configured to grasp the base 204 of apartially assembled cartridge in a manner similar to the reservoirsubstrate gripper 2420 described above. Further, the reservoir substrategripper 2420′ may include a finger 2424′ configured to releasably retainthe reservoir substrate 214 in the wrapped configuration. In thisregard, an innermost portion 2434 a′ of the finger 2424′ may beconfigured to press against the reservoir substrate 214. However, anoutermost portion 2434 b′ may be configured to deflect outside of, andaway from the outer body coupling tool 2406 when the outer body robot1314 directs the partially assembled cartridge through the outer bodycoupling tool. In this regard, as a result of the deflection, the finger2424′ may release from the reservoir substrate 214. Accordingly,insertion of the partially assembled cartridge through the outer bodycoupling tool 2406 may be accomplished in substantially the same manner.

Once the partially assembled cartridge is inserted into the outer body216, the crimper 2408 may crimp the outer body to the base 204. In thisregard, as illustrated in FIGS. 65 and 66, the crimper 2408 may comprisemultiple sections 2408 a. For example, the crimper 2408 may comprise atleast four sections 2408 a, which may facilitate production of a tightseal between the base and the outer body 216. Each of the sections 2408a may include a lip, angled portion, and some or all of the features ofthe crimper 1118 described above (see, FIGS. 37-39). Accordingly, thesections 2408 a may move from an open configuration (see, e.g., FIG. 65)to a closed configuration (see, e.g., FIG. 66) to crimp the outer body216 to the base 204. Note, however, the crimper 2408 may be invertedrelative to the above described crimper 1118. Further the crimper 2408may be configured to hold the outer body 216 during the insertion of thepartially assembled cartridge through the outer body coupling tool 2406.Accordingly, the crimper 2408 may differ from the above-describedcrimper 1118 in one or more respects.

Note that the above-described cartridge assembly sub-systems 402, 402′may be combined and modified in a number of manners without varying fromthe scope of the present disclosure. In this regard, the heating elementhas been generally described above as being provided as a substantiallycontinuous coil of wire wound about a substantially continuous liquidtransport element. Thus, preparation of individual heating elements 240and liquid transport elements 238 involved cutting a substantiallycontinuous input into sections. However, in other embodiments theheating elements may be formed by the cartridge assembly subsystem.

For example, as illustrated in FIG. 70, in one embodiment a heatingelement 240′ may be formed by providing a liquid transport element 238and coupling a wire 242 thereto to form the heating element. By way offurther example, in one embodiment an end 240A of the wire 242 may beinserted through the liquid transport element 238. Thereafter, one orboth of the liquid transport element 238 and the wire 242 may be rotatedto define the coils of the heating element 240′. Further, a second end240B of the wire 242 may be inserted back through the liquid transportelement 238 such that both the first end 240A and the second end 240B ofthe wire are held in place and the heating element is held in the coiledconfiguration. Alternatively, one or both of the ends of the wire may bewelded to an adjacent coil to hold the heating element in place and inthe coiled configuration.

Accordingly, the above-described process may produce a heating element240′ coupled to a liquid transport element 238, which may form acompleted atomizer when heating terminals (e.g., heating terminals 234a, 234 b) are coupled thereto (e.g., in via the processes disclosedherein). In this regard, as described above, the wire 242 may extend atleast partially through the liquid transport element 238 at one or bothof first and second ends 240A, 240B of the wire. Thus, the ends of thewire 242 may extend through the liquid transport element 238substantially transversely to a longitudinal length of the liquidtransport element. The liquid transport element 238 may extend betweenfirst and second opposing ends 238A, 238B. However, the wire 242 may notextend to the opposing ends of the liquid transport element (note that asection of the transport element is shown in FIG. 70, rather than a fulllength thereof) in order to prevent inclusion of unnecessary wire, asdescribed below. The heating element 240′ may comprise two contactportions 244A, 244B positioned proximate the ends of the wire 242 and acenter portion 246 positioned between the contact portions. Asillustrated, the contact portions 244A, 244B may define a first coilspacing and the center portion 246 may define a second coil spacing,wherein the second coil spacing is greater than the first coil spacing.As described elsewhere herein with respect to another embodiment of aheating element, this may facilitate attachment of the heating elementto the heating terminals at the contact portions. Further, by formingthe heating element 240′ in a manner whereby the wire 242 terminates atthe contact portions 244A, 244B of the heating element, less of the wire242 may be required to form the heating element, as compared toembodiments in which the wire extends along substantially the entirelength of the liquid transport element. In this regard, wire positionedoutside of the heating terminals may be wasted material in a completedatomizer, since wire at these locations would not function to facilitatecoupling to the heating terminals or produce heat.

Following attachment of the outer body 216 to the base, the partiallyassembled cartridge may be directed to the cartridge filling substation408. The cartridge filling substation 408 may include one or more fillstations. As illustrated in FIG. 71, in one embodiment the cartridgefilling substation 408 may include five filling stations 2502 a-e.Further, in some embodiments the cartridge filling substation 408 mayinclude an environment control housing 2504 in which the fillingstations 2502 a-e are positioned. Accordingly, an environment within theenvironment control housing 2504 may be controlled. Additionally, anenvironment modification apparatus 2506 may be configured to affect theenvironment within the environment control housing 2504. In someembodiments the controller 417 may be configured to control one or moreof the stations 2502 a-e and/or the environment modification apparatus2506 of the cartridge filling substation 408.

In one embodiment the environment modification apparatus 2506 maycomprise a dehumidifier configured to affect the ambient environmentwithin the environment control housing 2504. By way of additionalexample, the environment modification apparatus 2506 may be configuredto control the ambient environment within the environment controlhousing 2504 such that the ambient environment defines a relativehumidity of less than about 60%, preferably less than about 50% and mostpreferably less than about 40%. By controlling the humidity in thismanner, issues with respect to the aerosol precursor compositionabsorbing ambient moisture, which may undesirably dilute the aerosolprecursor composition and/or overfill the cartridge, may be avoided.

FIG. 72 illustrates an overhead view of a partially assembled cartridge,during filling and prior to coupling of a mouthpiece thereto. Asillustrated, an outlet 2508 of a filling device 2510 (e.g., a fillingneedle) may be positioned in proximity to a plurality of angularportions 2512 a-d (e.g., quadrants) of the reservoir substrate 214,wherein the angular portions are defined relative to a longitudinal axisextending through the cartridge. For example, as illustrated in FIG. 72,the outlet 2508 of the filling device 2510 may be sequentiallypositioned at a first angular portion 2512 a, followed by a secondangular portion 2512 b, a third angular portion 2512 c, and a fourthangular portion 2512 d. Directing the aerosol precursor composition at aplurality of angular positions may increase a fill rate of the reservoirsubstrate 214 with the aerosol precursor composition. In this regard,the absorbency rate of the reservoir composition 214 may be less than aflow rate out of the outlet 2508 of the filling device 2510.Accordingly, by moving the outlet 2508 to various angular portions 2512a-d, each angular portion may receive a flow of the aerosol precursorcomposition, to avoid issues with respect to a single angular portion ofthe reservoir substrate 214 being unable to absorb the aerosol precursorcomposition at the rate at which the filling device 2510 dispenses theaerosol precursor composition.

In one embodiment, the outlet 2508 of the filling device 2510 may besequentially moved from each of the first through fourth angularportions 2512 a-d at filling station one 2502 a. Thereafter, fillingstations two through five 2502 b-e may position the outlet 2508 of thefilling device 2510 at one of the angular portions. For example, fillingstation two 2502 b may position the outlet 2508 of the filling device2510 at the first angular portion 2512 a, filling station three 2502 cmay position the outlet 2508 of the filling device 2510 at the secondangular portion 2512 b, filling station four 2502 d may position theoutlet 2508 of the filling device 2510 at the third angular portion 2512c, and filling station five 2502 e may position the outlet 2508 of thefilling device 2510 at the fourth angular portion 2512 d. Accordingly,the cartridge may be transported between the filling stations 2502 a-eand the flow of the aerosol precursor composition may be directed to atleast one of the angular portions 2512 a-d of the reservoir substrate214 at each of the filling stations.

Further, as illustrated in FIG. 73, the outlet 2508 of the fillingdevice 2510 may remain out of contact with the reservoir substrate 214while directing a flow of an aerosol precursor composition 2514 throughthe outlet of the filling device at each of the angular portions of thereservoir substrate. In this regard, by avoiding contact with thereservoir substrate 214, damage thereto may be avoided. Further, asillustrated in FIGS. 72 and 73, the filling device 2510 may beconfigured to press against an inner surface of the outer body 216 whenfilling at each of the angular portions 2512 a-d. Accordingly, thecartridge may tilt slightly and the aerosol precursor composition 2514may be directed down the internal surface of the outer body 216, suchthat the reservoir substrate 214 may be filled at a relatively fasterrate.

After filling, the cartridge may be directed to the cartridge cappingsubsystem 412, at which the mouthpiece 220 is coupled to the outer body216. The outer body 216 may be crimped to the mouthpiece 220 using acrimper substantially similar to the above-described crimpers in orderto prevent leakage between the outer body and the mouthpiece. Further,the cartridge labeling subsystem 416 may apply a label 218 to thecartridge in some embodiments.

Various quality control measures may be employed to ensure that thecompleted cartridges 200 are suitably constructed. In this regard, asnoted above and illustrated in FIG. 3, the system 400 may additionallyinclude an inspection subsystem 418, which may inspect the components406, the unfilled cartridges 404, the filled cartridges 410, the cappedcartridges 414, and/or the completed cartridges 200. Further, in someembodiments the cartridges may be inspected at intermediate states ofcompletion at one or more of the cartridge assembly subsystem 402, thecartridge filling subsystem 408, the cartridge capping subsystem 412,and the cartridge labeling subsystem 416. Accordingly, the cartridgesand components thereof may be inspected before, during, and aftercompletion thereof.

In this regard, imaging devices (e.g., cameras) may be employed at avariety of locations to ensure that the above-described processes arebeing performed as desired, within specifications. Thus, cameras and/orother inspection equipment may be employed at a plurality of locationswithin the system 400. However, inspection at certain locations may beof particular importance.

In this regard, it may be important to inspect the position of theterminals 206, 234 a, 234 b after insertion into the base 204. Forexample, one or more cameras may be configured to inspect a radialposition of each of the terminals 206, 234 a, 234 b (e.g., with respectto a center of the base 204). The radial position of the terminals 206,234 a, 234 b may be determined at an attachment end 204 a of the base204. In this regard, proper radial position of the terminals 206, 234 a,234 b may facilitate attachment of the cartridge 200 to the controlcomponent 300. Further, one or more cameras may be employed to inspectthe distance to which the terminals 206, 234 a, 234 b extend from thebase 204. The distance to which the terminals 206, 234 a, 234 b extendfrom the base 204 may be determined at an inner end 204 b (see, FIG. 1)in some embodiments. In this regard, extension of the terminals 206, 234a, 234 b to the proper distance from the inner end 204 b of the base 204may be important for ensuring a proper coupling of the heating element240 thereto.

In the cartridge assembly subsystem 402, the terminals 206, 234 a, 234 bare downwardly inserted into the base 204. Accordingly, inspection ofthe distance to which the terminals 206, 234 a, 234 b extend from theinner end 204 b of the base 204 may be conducted while the base is heldin the carriage 600 traveling on the rail 616. In this regard, asillustrated in FIG. 74, a side view camera 2602 may be configured tocapture images of a side profile of the partially assembled cartridgefollowing coupling of one or more of the terminals 206, 234 a, 234 b tothe base 204. Thereby, a controller may be configured to determine adistance to which one or more of the terminals 206, 234 a, 234 b extendfrom the base 204.

However, as a result of the attachment end 204 a of base 204 beingdownwardly oriented toward the carriage 600, the base may be removedfrom the carriage to inspect the radial position of the terminals 206,234 a, 234 b. In this regard, as illustrated in FIG. 75, a removal robot2604 may be configured to remove the partially assembled cartridge fromthe carriage 600 and move the partially assembled cartridge over an endview camera 2606. Accordingly, images captured by the end view camera2604 may be analyzed by a controller to determine a radial position ofone or more of the terminals 206, 234 a, 234 b. Alternatively, anaperture extending through the carriage 600 may allow for inspection ofthe radial position of the terminals 206, 234 a, 234 b at the attachmentend 204 a of the base 204. Further, note that in some embodiments aseparate camera may be provided for each terminal in order to focus oneach particular terminal. In other embodiments a camera may be employedto inspect multiple terminals, for example by adjusting the focus of thecamera.

In the second embodiment of the cartridge assembly subsystem 402′, thecartridge is generally assembled with the base 204 oriented in anopposing manner such that components coupled thereto extend downwardlytherefrom. In this regard, as illustrated in FIG. 76, the fixtures 1704of one or more of the transfer members 1700A-C may be employed tofacilitate inspection of the terminals 206, 234 a, 234 b. For example,the fixtures 1704 may hold the base 204 such that the attachment end 204a thereof extends upwardly. Accordingly, an end view camera 2702positioned above the base 204 may inspect the radial position of theterminals 206, 234 a, 234 b.

Further, as illustrated in FIG. 77, the fixtures 1704 may include one ormore apertures 2704 a, 2704 b extending therethrough. Accordingly, asillustrated in FIG. 76, a side view camera 2706 may be positioned tolook through one or more of the apertures 2704 a, 2704 b to determine adistance to which the terminals 206, 234 a, 234 b extend from the innerend 204 b of the base 204. In some embodiments a separate camera may beprovided for each terminal in order to focus on each particularterminal. In other embodiments a camera may be employed to inspectmultiple terminals, for example by adjusting the focus of the camera.

The inspection subsystem 418 may additionally include one or morecameras configured to inspect the partially assembled cartridgefollowing crimping of the outer body 216 to the base 204. For example,as illustrated in FIG. 78, when inspecting the first embodiment of thecartridge assembly subsystem 402, the inspection subsystem 418 mayinclude an end view camera 2802 configured to capture images inside ofthe outer body 216. In this regard, the end view camera 2802 may bepositioned above the rail 616 downstream of the crimper 1118, such thatwhen a carriage 600 is directed under the end view camera, the end viewcamera may capture one or more images of the inside of the outer body216. Thereby, a controller may determine whether or not the reservoirsubstrate 214 is present, which is a desired condition, or missing,which is an undesired condition.

Further, the cartridge assembly subsystem 402 may include a side viewcamera 2804 configured to capture images of a side of the partiallyassembled cartridge. In this regard, the side view camera 2804 may bepositioned beside the rail 616 such that the side view camera maycapture images of the partially assembled cartridge held by the carriage600. In this regard, a controller may be configured to analyze theimages captured by the side view camera 2804 to determine whether acrimp in the outer body 216 produced by the crimper 1118 is proper(e.g., when the crimp is proper the outer body may be substantiallyflush with the base 204) and further the controller may determinewhether the reservoir substrate 214 sticks out of the outer body (e.g.,at the interface between the outer body and the base), which is anundesired condition, or contained within the outer body, which is adesired condition.

As illustrated in FIG. 79, when inspecting the second embodiment of thecartridge assembly subsystem 402′, the inspection subsystem 418 mayinclude an end view camera 2902 configured to capture images inside ofthe outer body 216 and a side view camera 2904 configured to captureimages of the side of the partially assembled cartridge such that acontroller may analyze the images of the partially assembled cartridgein the manner described above. Further, an outer body inspection robot1316 may be employed to receive the partially assembled cartridge fromthe crimper 2408 and direct the partially assembled cartridge to aposition at which the end view camera 2902 and the side view camera 2904may capture images of the partially assembled cartridge. Further, theouter body inspection robot 1316 may include the base gripper 1500 insome embodiments, which may facilitate gripping the base 204 in themanner described above.

The inspection subsystem 418 may additionally include a blow-throughstation. The blow-through station may be configured to direct a flow ofair through the cartridge to purge the flow path defined therethrough.In this regard, although not expected, the blow-through station mayremove any dust or debris from the flow path through the cartridge. Byway of example, FIG. 80 illustrates a blow-through station 3000 that maybe employed with the first embodiment of the cartridge assemblysubsystem 402. As illustrated, the blow-through station 3000 may includea first connector 3002 and a second connector 3004. In one embodiment,the first connector 3002 may be configured to engage an aperture 3006 inthe carriage 600 in communication with the attachment end 204 a of thebase 204. In this regard, the first connector may include an elastomericseal 3008 configured to engage the aperture 3006 in the carriage 600 insome embodiments. Further, the second connector 3004 may be configuredto engage an end of the outer body 216 opposite from the base 204, forexample via an elastomeric seal.

The connectors 3002, 3004 may be at differing pressures. Accordingly, apressure differential applied across the cartridge through theconnectors 3002, 3004 may cause a flow of air to be directedtherethrough. In some embodiments the first connector 3002 may be at ahigher pressure than the second connector 3004 such that air flowsthrough the cartridge in the same direction as would occur during normaluse of the cartridge. For example, vacuum may be applied to the secondconnector 3004, whereas the first connector 3002 may be ambientpressure. Accordingly, any debris in the cartridge may be removed.

FIG. 81 illustrates an embodiment of a blow-through station 3100 whichmay be included with the second embodiment of the cartridge assemblysubsystem 402′. As illustrated, the blow-through station 3100 mayinclude a first connector 3102 and a second connector 3104. Further, theblow-through station 3100 may include a rotatable arm 3106 and an outerbody gripper 3108. The outer body inspection robot 1316 may move thepartially assembled cartridge to the blow-through station 3100. Thus,the outer body gripper 3108 may grasp the outer body 216 of thepartially assembled cartridge and the rotatable arm 3106 may rotate thepartially assembled cartridge into place between the connectors 3102,3104. The connectors 3102, 3104 may contract against the ends of thecartridge to form a seal therewith. For example, the connectors 3102,3104 may respectively include an elastomeric seal 3110, 3112 thatfacilitate formation of connections with the attachment end 204 a of thebase 204 and the opposite end of the outer body 216. Followingcompletion of the blow-through in the manner described above, connectors3102, 3104 may retract and the rotatable arm 3106 may rotate thepartially assembled cartridge such that the cartridge may be grasped andmoved to an additional station. Note that, as illustrated, an additionalblow-through station 3100′, which may be substantially similar to theblow-through station 3100 may be provided in order to increasethroughput.

Further, the inspection subsystem 418 may additionally include apressure drop station. The pressure drop station 418 may be configuredto detect a pressure drop associated with directing airflow through thepartially assembled cartridge. Accordingly, a pressure drop associatedwith the cartridge may be determined and compared to a desired pressuredrop to ensure that there are not any obstructions or leaks in thecartridge.

In some embodiments the pressure drop station may be substantiallysimilar to the flow-through station. In this regard, FIG. 82 illustratesa pressure drop station 3200 that may be employed with the firstembodiment of the cartridge assembly subsystem 402. As illustrated, thepressure drop station 3200 may include a first connector 3202 and asecond connector 3204. In one embodiment, the first connector 3202 maybe configured to engage an aperture in the carriage (see, e.g., aperture3006 in carriage 600 FIG. 80) in communication with the attachment end204 a of the base 204. In this regard, the first connector 3202 mayinclude an elastomeric seal 3208 configured to engage the aperture inthe carriage in some embodiments. Further, the second connector 3204 maybe configured to engage an end of the outer body 216 opposite from thebase 204, for example via an elastomeric seal.

One of the connectors 3202, 3204 may supply air to the cartridge at aknown flow rate and/or pressure. Further, the flow rate and/or thepressure of the air traveling through the other of the connectors 3202,3204 may be tested to determine the pressure drop associated with thecartridge. Thereby, the pressure drop may be compared to a desiredpressure drop.

FIG. 83 illustrates an embodiment of a pressure drop station 3300 whichmay be included with the second embodiment of the cartridge assemblysubsystem 402′. As illustrated, the pressure drop station 3300 mayinclude a first connector 3302 and a second connector 3304. Further, thepressure drop station 3300 may include a rotatable arm 3306 and an outerbody gripper 3308. Accordingly, an inspection robot 1318 (see, FIG. 41)may move the partially assembled cartridge from the blow-through station3100 to the pressure drop station 3300. Thus, the outer body gripper3308 may grasp the outer body 216 of the partially assembled cartridgeand the rotatable arm 3306 may rotate the partially assembled cartridgeinto place between the connectors 3302, 3304, which may move together toseal against the ends of the cartridge. For example, the connectors3302, 3304 may respectively include an elastomeric seal 3310, 3312 thatfacilitate formation of connections with the attachment end 204 a of thebase 204 and the opposite end of the outer body 216. Followingcompletion of the pressure drop test in the manner described above, theconnectors 3302, 3304 may retract and the rotatable arm 3106 may rotatethe partially assembled cartridge such that the cartridge may be graspedand moved to an additional station. Note that, as illustrated, anadditional pressure drop station 3300′, which may be substantiallysimilar to the pressure drop station 3300 may be provided in order toincrease throughput.

Further, the inspection subsystem 418 may additionally include anelectrical test station. In this regard, FIG. 84 illustrates anembodiment of an electrical test station 3400 that may be included withthe first embodiment of the cartridge assembly subsystem 402. Asillustrated, the electrical test station 3400 may include a test fixture3402. Further, electrical test station 3400 may include a robotic arm3404 configured to move the partially assembled cartridge from thecarriage to the test fixture 3402 and back. The robotic arm 3404 mayinclude an outer body gripper 3406, which may be configured to grasp anouter surface of the outer body 216.

FIG. 85 illustrates an enlarged view of the test fixture 3402. Asillustrated, the test fixture 3402 may comprise a receptacle 3408configured to engage the base 204 of the cartridge. FIG. 86 illustratesa cross-sectional view through the test fixture 3402. In this regard,the receptacle 3408 may define a shape and size that is similar to thatof the coupler 302 of the control body 300. However, the receptacle 3408may be relatively shorter than the coupler 302 in order to avoiddamaging optional crush members in the base 204. Further, the receptacle3408 may not include anti-rotation features, such that the cartridge mayengage the base 204 at any rotational position.

As illustrated, the test fixture 3402 may comprise a plurality ofelectrical contacts coupled to the receptacle 3408 and configured toengage terminals of the cartridge. For example, a first electricalcontact 3410 may be configured to engage the first heating terminal 234a, a second electrical contact 3412 may be configured to engage thesecond heating terminal 234 b, and a third electrical contact 3414 maybe configured to engage a control component terminal 206. The firstelectrical contact 3410 may be defined by a first body portion 3416, thesecond electrical contact 3412 may be defined by a second body portion3418, and the third electrical contact 3414 may be defined by a thirdbody portion 3420. The body portions 3416, 3418, 3420 may be formed fromconductive and relatively hard material, such as hardened steel, inorder to withstand repeated use and allow for electrical communicationtherethrough in the manner described below.

Each of the body portions 3416, 3418, 3420 may be coupled to anonconductive member 3422, which may be formed from any of a variety ofnonconductive materials such as plastic. Further, the body portions3416, 3418, 3420 may be electrically insulated from another by avoidingdirect contact therebetween. In this regard, the body portions 3416,3418, 3420 may be positioned such that air gaps are definedtherebetween. For example, the body portions 3416, 3418, 3420 may becoupled to the nonconductive member 3422 such that the body portions arespaced apart from one another when coupled to the nonconductive member.Alternatively or additionally, nonconductive spacers may be placedbetween the body portions 3416, 3418, 3420.

The test fixture 3402 may be in communication with a controller such asthe above-described controller 417 (see, e.g., FIG. 3). The controller417 may be configured to communicate with the cartridge through theelectrical contacts 3410, 3412, 3414 when the base of the cartridge isengaged with the receptacle 3402. Thereby, the cartridge may be testedand various other functions may be performed. For example, thecontroller 417 may be configured to determine a resistance of theatomizer of the cartridge and compare the resistance to a desiredresistance. In some embodiments the resistance of the atomizer maypreferably be from 1.5 ohms to about 3.5 ohms and more preferably fromabout 2.1 ohms to about 3.0 ohms, which may correspond to an atomizerconfigured to produce a desired amount of heat. Further, the controller417 may be configured to determine if the atomizer is shorted to theouter body of the cartridge. In this regard, the controller 417 maycheck to make sure that a resistance between the outer body and one ormore of the terminals 206, 234 a, 234 b is greater than about one megaohm. For example, current may be applied through the outer body gripper3406 to the outer body 216 of the cartridge and the controller 417 maydetect any current reaching one or more of the terminals 206, 234 a, 234b to determine the resistance between the terminals and the outer body.In this regard, in an improperly assembled cartridge the atomizer maytouch the outer body, which could cause current to be transferredtherebetween.

The test fixture 3402 may further comprise an aperture 3426 configuredto provide for a flow of air through the base 204 of the cartridge.Accordingly, in some embodiments the test fixture 3402 may be employedto perform the above-described flow-through and/or pressure dropoperations. Thus, for example, the aperture 3426 in the test fixture maybe in communication with a first connector and the outer body gripper3406 may include a second connector, such that an air flow may beprovided through a cartridge held by the test fixture 3402 and the outerbody gripper.

Further, the controller 417 may be configured to transmit program codeinstructions to the electronic control component 208 of the cartridgethrough the third electrical contact 3414 and the control componentterminal 206. Accordingly, for example, a heating profile defining whenand how much current to apply to the atomizer upon detection of a puffmay be written to the electronic control component 208. Additionally,the program code instructions may include an authentication code, whichmay be employed to verify that the cartridge is authentic. Thecontroller 417 may be further configured to read program codeinstructions stored on the electronic control component 208 anddetermine whether the program code instructions stored on the electroniccontrol component correspond to desired program code instructions. Forexample, reading the stored program code instructions may be employed toensure that the proper heating profile and authentication code arestored. A unique identifier associated with the electronic controlcomponent 208 may also be read therefrom, which may be employed torecord information regarding the cartridge (e.g., manufacture date,heater profile, authentication code, etc.) in a database. The controller417 may also initialize the electronic control component 208 such thatthe electronic control component directs current to the atomizer upondetection of a first puff, rather than a second puff, which may occurwhen the electronic control component is not initialized.

FIG. 87 illustrates an embodiment of an electrical test station 3500that may be included in the inspection subsystem 418 with the secondembodiment of the cartridge assembly subsystem 402′. Cartridges may bedelivered to the electrical test station 3500 by the above-describedinspection robot 1318. In this regard, the inspection robot 1318 maydeposit the cartridges on a test fixture 3502. A gripper 3504 may beconfigured to press and hold the cartridge on a receptacle 3506 of thetest fixture 3502. The functionality and structure of the test fixture3502 may be substantially similar to the above-described test fixture3402. Accordingly, description thereof will not be repeated. However,the test fixture 3502 may further comprise a slot 3508 positioned onopposing sides of the receptacle 3506. The slot 3508 may be configuredto receive a gripper 3510 of a test fixture robot 1320 such that thegripper may grasp beneath the base to remove the cartridge from thereceptacle. Accordingly, the gripper 3510 may pull the cartridge off ofthe receptacle 3506. Note that, as illustrated, an additional testfixture 3500′, which may be substantially similar to the test fixture3500 may be provided in order to increase throughput.

In some embodiments the inspection subsystem 418 may additionallyinclude a quality assurance station. The quality assurance station maybe positioned at any point in the assembly process. For example, thequality assurance station may be positioned downstream of the crimper1118, 2408 that crimps the outer body 216 to the base 204. However, thequality assurance station may be configured to receive partiallyassembled cartridges in various states of completion. In this regard,the various substations of the cartridge assembly subsystems 402, 402′may be configured to direct the cartridges to quality assurance stationin any of the various states of completion occurring during the assemblythereof. Thus, for example, a base 204 with the terminals 206, 234 a,234 b coupled thereto may be directed to the quality assurance stationwithout the electronic control component, flow tube, reservoirsubstrate, and outer body coupled thereto. By way of further example,the carriages 600 of the first embodiment of the cartridge assemblysubsystem 402 may skip various stations, and/or some of the robots ofthe second embodiment of the cartridge assembly subsystem 402′ maytransfer the partially assembled cartridge to the quality assurancestation without performing operations thereon. The partially assembledcartridges directed to the quality assurance station may be inspectedmanually, or via automated processes, to ensure that the cartridges arebeing properly assembled. In some embodiments the partially assembledcartridges, defining various states of completion, may be directed tothe quality assurance substation at predefined intervals, such thatpartially assembled cartridges in each of various states of completion,may be regularly inspected.

The inspection subsystem 418 may be configured to dispose of defectivecartridges that fail to meet certain predefined standards, as describedabove. For example, after a partially assembled cartridge is identifiedas defective in the first embodiment of the cartridge assemblysubsystems 402, the carriage 600 holding the defective cartridge mayskip the remaining assembly stations and direct the cartridge to areject station at which the defective cartridge is removed thereform(e.g., via a vacuum hose) for disposal. By way of further example, aftera partially assembled cartridge is identified as defective in the secondembodiment of the cartridge assembly subsystems 402′, a robot proximatethe location at which the cartridge is determined to be defective maydrop the defective cartridge in a waste receptacle. For example, FIG. 79illustrates a receptacle 3600 in a table 3602 supporting the cartridgeassembly subsystems 402′ in which defective cartridges may be deposited(e.g., following inspection of the terminals 206, 234 a, 234 b). In thisregard, a receptacle may be associated with each location at which thecartridges are inspected such that the defective cartridges may beimmediately disposed of.

The inspection subsystem 418 may additionally inspect the cartridgesfollowing filling at the cartridge filling subsystem 408, capping at thecartridge capping subsystem 410, and/or labeling at the cartridgelabeling subsystem 412. For example, the inspection subsystem 418 may beconfigured to detect leaks in the cartridge after filling. By way offurther example, the inspection subsystem 418 may include a camera overwhich the filled cartridges are lifted and the captured images may becompared to stored images of known acceptable cartridges that do nothave leaks. Additional cameras may ensure that the mouthpiece 220 isproperly crimped to the outer body 216. For example, the crimpassociated with attachment of the mouthpiece 220 to the outer body 216may be inspected in substantially the same manner as the crimp employedto attach the base 204 to the outer body. Further, following applicationof the label 218 to the outer body 216, a camera may inspect theplacement of the label to ensure that it is properly positioned.

A method for assembling a cartridge for an aerosol delivery device isalso provided. As illustrated in FIG. 88, the method may compriseproviding a reservoir substrate extending at least partially about anatomizer at operation 3702. Further, the method may include providing anouter body configured to at least partially receive the reservoirsubstrate and the atomizer therein at operation 3704. Additionally, themethod may include inserting the reservoir substrate through a tool intothe outer body, the tool defining a funnel portion configured to reducean outer dimension of the reservoir substrate such that the outerdimension of the reservoir substrate is less than or equal to aninternal dimension of the outer body to facilitate insertion of thereservoir substrate into the outer body at operation 3706.

In some embodiments the method may additionally include twisting thetool relative to the reservoir substrate while inserting the reservoirsubstrate through the tool into the outer body at operation 3706.Providing the reservoir substrate extending at least partially about theatomizer at operation 3702 may comprise wrapping the reservoir substrateat least partially about the atomizer prior to inserting the reservoirsubstrate through the tool into the outer body at operation 3706.Wrapping the reservoir substrate at least partially about the atomizermay comprise directing a flow of air at the reservoir substrate.

The method may further comprise engaging the reservoir substrate withone or more fingers such that the reservoir substrate remains at leastpartially wrapped about the atomizer when beginning to insert thereservoir substrate through the tool into the outer body at operation3706. Further, the method may include releasing the one or more fingersfrom the reservoir substrate when the reservoir substrate is inserted toa predetermined depth in the tool. Releasing the one or more fingers maycomprise deflecting the one or more fingers away from the reservoirsubstrate by contacting the one or more fingers with the tool. Further,releasing the one or more fingers may comprise sequentially releasingthe fingers. The method may further comprise coupling the atomizer to abase prior to wrapping the reservoir substrate at least partially aboutthe atomizer and coupling the outer body to the base after inserting thereservoir substrate through the tool into the outer body at operation3706. Additionally, the method may include supplying the reservoirsubstrate from a substantially continuous reservoir substrate input andcontrolling a tension in the substantially continuous reservoirsubstrate input.

A method for assembling an atomizer for an aerosol delivery device isalso provided. As illustrated in FIG. 89, the method may includeproviding a first heating terminal, a second heating terminal, and aheating element at operation 3802. Further, the method may includedetermining a position of the first heating terminal and the secondheating terminal at operation 3804. The method may also includedetermining a position of the heating element at operation 3806.Additionally, the method may include affixing the heating element to thefirst heating terminal and the second heating terminal (e.g., such thatan electrical connection is established therebetween) based on theposition of the first heating terminal and the second heating terminaland the position of the heating element at operation 3808.

Determining the position of the first heating terminal and the secondheating terminal at operation 3804 may comprise determining a midpointbetween a first heating terminal tab and a second heating terminal tab.The heating element may comprise a first contact portion and a secondcontact portion, and determining the position of the heating element atoperation 3806 may comprise determining a midpoint between the firstcontact portion and the second contact portion. The method may furthercomprise aligning the midpoint between the first heating terminal taband the second heating terminal tab with the midpoint between the firstcontact portion and the second contact portion, engaging the firstcontact portion with the first heating terminal tab, and engaging thesecond contact portion with the second heating terminal tab.

The method may further comprise clamping the first heating terminal andthe second heating terminal such that the first heating terminal tab andthe second heating terminal tab are substantially coplanar. Clamping thefirst heating terminal and the second heating terminal may compriseadjusting a spacing between the first heating terminal and the secondheating terminal. Affixing the heating element to the first heatingterminal and the second heating terminal at operation 3808 may comprisedirecting a plurality of laser beams at the first heating terminal taband at the second heating terminal tab. Directing the laser beams at thefirst heating terminal tab and at the second heating terminal tab maycomprise directing the laser beams at a backside of the first heatingterminal tab and the second heating terminal tab opposite from theheating element. The method may further comprise inserting the heatingelement, the first heating terminal, and the second heating terminalinto a substantially sealed chamber before directing the laser beams atthe first heating terminal tab and at the second heating terminal tab.

Providing the heating element at operation 3802 may comprise supplyingthe heating element from a substantially continuous heating elementinput and controlling a tension in the substantially continuous heatingelement input. The method may further comprise coupling the heatingelement to a liquid transport element. Coupling the heating element tothe liquid transport element may comprise inserting an end of theheating element through the liquid transport element and rotating atleast one of the heating element and the liquid transport element suchthat the heating element winds about the liquid transport element.Providing the first heating terminal and the second heating terminal atoperation 3802 may comprise supplying the first heating terminal from asubstantially continuous first heating terminal input and supplying thesecond heating terminal from a substantially continuous second heatingterminal input.

In some embodiments the heating element may comprise a wire wound abouta liquid transport element. The wire may comprise two contact portions,a center portion, and two outer portions positioned outside of thecontact portions, the two contact portions and the center portion of thewire defining the heating element. The contact portions may define afirst coil spacing, the center portions may define a second coilspacing, and the outer portions may define a third coil spacing. Thethird coil spacing may be greater than the second coil spacing and thesecond coil spacing may be greater than the first coil spacing. Further,affixing the heating element to the first heating terminal and thesecond heating terminal at operation 3808 may comprise affixing thecontact portions to the first heating terminal and the second heatingterminal.

A cartridge filling method is also provided. As illustrated in FIG. 90,the method may include providing a cartridge for an aerosol deliverydevice comprising a reservoir substrate positioned in an outer body atoperation 4002. Further, the method may include sequentially positioningan outlet of a filling device in proximity to a plurality of angularportions of the reservoir substrate at operation 4004. The method mayadditionally include directing a flow of an aerosol precursorcomposition through the outlet of the filling device at each of theangular portions of the reservoir substrate at operation 4006.

In some embodiments the outlet of the filling device may remain out ofcontact with the reservoir substrate. Further, the method may includetransporting the cartridge between a plurality of filling stations,wherein the flow of the aerosol precursor composition is directed to atleast one of the angular portions of the reservoir substrate at each ofthe filling stations. Additionally, the flow of the aerosol precursorcomposition may be directed at each of the angular portions of thereservoir substrate at a first one of the filling stations. The flow ofthe aerosol precursor composition is respectively directed to one of theangular portions of the reservoir substrate at a remainder of the filingstations. The method may further comprise controlling an ambientenvironment in which the cartridge is filled such that the ambientenvironment defines a relative humidity of less than about 40%.

A method for assembling a cartridge for an aerosol delivery device isalso provided. As illustrated in FIG. 91, the method may includegrasping a base at operation 4102. Further, the method may includeproviding a plurality of components configured to engage the base, thecomponents being provided in a stationary position at operation 4104.Additionally, the method may include coupling the components to the baseby directing the base into contact with the components in the stationaryposition at operation 4106.

Grasping the base at operation 4102 may comprise grasping an internalsurface of an attachment end of the base configured to engage a controlbody. Directing the base into contact with the components in thestationary position at operation 4106 may comprise directing the basedownwardly into contact with the components. The method may furthercomprise inserting the base into a fixture and inspecting a position offirst and second heating terminals coupled to the base through thefixture.

As noted above, the system 400 may include a controller 417. Thecontroller 417 may be configured to execute computer code for performingthe operations described herein. In this regard, as illustrated in FIG.92, the controller 417 may comprise a processor 4202 that may be amicroprocessor or a controller for controlling the overall operationthereof. In one embodiment the processor 4202 may be particularlyconfigured to perform the functions described herein. The controller 417may also include a memory device 204. The memory device 4204 may includenon-transitory and tangible memory that may be, for example, volatileand/or non-volatile memory. The memory device 4204 may be configured tostore information, data, files, applications, instructions or the like.For example, the memory device 4204 could be configured to buffer inputdata for processing by the processor 4202. Additionally oralternatively, the memory device 4204 may be configured to storeinstructions for execution by the processor 4202.

The controller 417 may also include a user interface 4206 that allows auser to interact therewith. For example, the user interface 4206 cantake a variety of forms, such as a button, keypad, dial, touch screen,audio input interface, visual/image capture input interface, input inthe form of sensor data, etc. Still further, the user interface 4206 maybe configured to output information to the user through a display,speaker, or other output device. A communication 4208 interface mayprovide for transmitting and receiving data through, for example, awired or wireless network 4210 such as a local area network (LAN), ametropolitan area network (MAN), and/or a wide area network (WAN), forexample, the Internet.

The various aspects, embodiments, implementations or features of thedescribed embodiments can be used separately or in any combination.Various aspects of the described embodiments can be implemented bysoftware, hardware or a combination of hardware and software. Thedescribed embodiments can also be embodied as computer readable code ona computer readable medium for controlling the above-describedoperations. In particular, computer readable code may be configured toperform each of the operations of the methods described herein andembodied as computer readable code on a computer readable medium forcontrolling the above-described operations. In this regard, a computerreadable storage medium, as used herein, refers to a non-transitory,physical storage medium (e.g., a volatile or non-volatile memory device,which can be read by a computer system. Examples of the computerreadable medium include read-only memory, random-access memory, CD-ROMs,DVDs, magnetic tape, and optical data storage devices. The computerreadable medium can also be distributed over network-coupled computersystems so that the computer readable code is stored and executed in adistributed fashion.

As noted above, the controller 417 may be configured to execute computercode for performing the above-described operations. In this regard, anembodiment of a non-transitory computer readable medium for storingcomputer instructions executed by a processor in a controller (e.g.controller 417) configured assemble a cartridge for an aerosol deliverydevice is provided. The non-transitory computer readable medium maycomprise program code instructions for providing a reservoir substrateextending at least partially about an atomizer; program codeinstructions for providing an outer body configured to at leastpartially receive the reservoir substrate and the atomizer therein; andprogram code instructions for inserting the reservoir substrate througha tool into the outer body, the tool defining a funnel portionconfigured to reduce an outer dimension of the reservoir substrate suchthat the outer dimension of the reservoir substrate is less than orequal to an internal dimension of the outer body to facilitate insertionof the reservoir substrate into the outer body.

The computer readable medium may further comprise program codeinstructions for twisting the tool relative to the reservoir substratewhile inserting the reservoir substrate through the tool into the outerbody. The program code instructions for providing the reservoirsubstrate extending at least partially about the atomizer may compriseprogram code instructions for wrapping the reservoir substrate at leastpartially about the atomizer prior to inserting the reservoir substratethrough the tool into the outer body. The program code instructions forwrapping the reservoir substrate at least partially about the atomizermay comprise program code instructions for directing a flow of air atthe reservoir substrate. The computer readable medium may furthercomprise program code instructions for engaging the reservoir substratewith one or more fingers such that the reservoir substrate remains atleast partially wrapped about the atomizer when beginning to insert thereservoir substrate through the tool into the outer body. The computerreadable medium may further comprise program code instructions forreleasing the one or more fingers from the reservoir substrate when thereservoir substrate is inserted to a predetermined depth in the tool.The program code instructions for releasing the one or more fingers maycomprise program code instructions for deflecting the one or morefingers away from the reservoir substrate by contacting the one or morefingers with the tool. The program code instructions for releasing theone or more fingers may comprise program code instructions forsequentially releasing the fingers. The computer readable medium mayfurther comprise program code instructions for coupling the atomizer toa base prior to wrapping the reservoir substrate at least partiallyabout the atomizer; and program code instructions for coupling the outerbody to the base after inserting the reservoir substrate through thetool into the outer body. The computer readable medium may furthercomprise program code instructions for supplying the reservoir substratefrom a substantially continuous reservoir substrate input; and programcode instructions for controlling a tension in the substantiallycontinuous reservoir substrate input.

In an additional embodiment, a non-transitory computer readable mediumfor storing computer instructions executed by a processor in acontroller (e.g. controller 417) configured to assemble an atomizer foran aerosol delivery device may comprise program code instructions forproviding a first heating terminal, a second heating terminal, and aheating element; program code instructions for determining a position ofthe first heating terminal and the second heating terminal; program codeinstructions for determining a position of the heating element; andprogram code instructions for affixing the heating element to the firstheating terminal and the second heating terminal based on the positionof the first heating terminal and the second heating terminal and theposition of the heating element. The program code instructions fordetermining the position of the first heating terminal and the secondheating terminal may comprise program code instructions for determininga midpoint between a first heating terminal tab and a second heatingterminal tab.

In some embodiments the heating element may comprise a first contactportion and a second contact portion, and the program code instructionsfor determining the position of the heating element may comprise programcode instructions for determining a midpoint between the first contactportion and the second contact portion. The computer readable medium mayfurther comprise program code instructions for aligning the midpointbetween the first heating terminal tab and the second heating terminaltab with the midpoint between the first contact portion and the secondcontact portion; program code instructions for engaging the firstcontact portion with the first heating terminal tab; and program codeinstructions for engaging the second contact portion with the secondheating terminal tab. The computer readable medium may additionallyinclude program code instructions for clamping the first heatingterminal and the second heating terminal such that the first heatingterminal tab and the second heating terminal tab are substantiallycoplanar. The program code instructions for clamping the first heatingterminal and the second heating terminal may comprise program codeinstructions for adjusting a spacing between the first heating terminaland the second heating terminal. The program code instructions foraffixing the heating element to the first heating terminal and thesecond heating terminal may comprise program code instructions fordirecting a laser beam at the first heating terminal tab and at thesecond heating terminal tab. The program code instructions for directingthe laser beam at the first heating terminal tab and at the secondheating terminal tab may comprise program code instructions fordirecting the laser beam at a backside of the first heating terminal taband the second heating terminal tab opposite from the heating element.The computer readable medium may further comprise program codeinstructions for inserting the heating element, the first heatingterminal, and the second heating terminal into a substantially sealedchamber before directing the laser beam at the first heating terminaltab and at the second heating terminal tab. The program codeinstructions for providing the heating element may comprise program codeinstructions for supplying the heating element from a substantiallycontinuous heating element input; and program code instructions forcontrolling a tension in the substantially continuous heating elementinput. The computer readable medium may further comprise program codeinstructions for coupling the heating element to a liquid transportelement. The program code instructions for coupling the heating elementto the liquid transport element may comprise program code instructionsfor inserting an end of the heating element through the liquid transportelement; and program code instructions for rotating at least one of theheating element and the liquid transport element such that the heatingelement winds about the liquid transport element. The program codeinstructions for providing the first heating terminal and the secondheating terminal may comprise program code instructions for supplyingthe first heating terminal from a substantially continuous first heatingterminal input; and program code instructions for supplying the secondheating terminal from a substantially continuous second heating terminalinput. The heating element may comprise a wire wound about a liquidtransport element. The wire may comprise two contact portions, a centerportion, and two outer portions positioned outside of the contactportions, the two contact portions and the center portion of the wiremay define the heating element, wherein the contact portions define afirst coil spacing, the center portion defines a second coil spacing,and the outer portions define a third coil spacing, the third coilspacing being greater than the second coil spacing and the second coilspacing being greater than the first coil spacing, and wherein affixingthe heating element to the first heating terminal and the second heatingterminal comprises affixing the contact portions to the first heatingterminal and the second heating terminal.

In an additional embodiment, a non-transitory computer readable mediumfor storing computer instructions executed by a processor in acontroller (e.g. controller 417) configured to fill a cartridge maycomprise program code instructions for providing a cartridge for anaerosol delivery device comprising a reservoir substrate positioned inan outer body; program code instructions for sequentially positioning anoutlet of a filling device in proximity to a plurality of angularportions of the reservoir substrate; and program code instructions fordirecting a flow of an aerosol precursor composition through the outletof the filling device at each of the angular portions of the reservoirsubstrate. The outlet of the filling device may remain out of contactwith the reservoir substrate. The computer readable medium may furthercomprise program code instructions for transporting the cartridgebetween a plurality of filling stations, wherein the flow of the aerosolprecursor composition is directed to at least one of the angularportions of the reservoir substrate at each of the filling stations. Theflow of the aerosol precursor composition may be directed at each of theangular portions of the reservoir substrate at a first one of thefilling stations. The flow of the aerosol precursor composition may berespectively directed to one of the angular portions of the reservoirsubstrate at a remainder of the filing stations. The computer readablemedium may further comprise program code instructions for controlling anambient environment in which the cartridge is filled such that theambient environment defines a relative humidity of less than about 40%.

In an additional embodiment, a non-transitory computer readable mediumfor storing computer instructions executed by a processor in acontroller (e.g. controller 417) configured to assemble a cartridge foran aerosol delivery device may comprise program code instructions forgrasping a base; program code instructions for providing a plurality ofcomponents configured to engage the base, the components being providedin a stationary position; and program code instructions for coupling thecomponents to the base by directing the base into contact with thecomponents in the stationary position. The program code instructions forgrasping the base may comprise program code instructions for grasping aninternal surface of an attachment end of the base configured to engage acontrol body. The program code instructions for directing the base intocontact with the components in the stationary position may compriseprogram code instructions for directing the base downwardly into contactwith the components. The computer readable medium may further compriseprogram code instructions for inserting the base into a fixture; andprogram code instructions for inspecting a position of first and secondheating terminals coupled to the base through the fixture.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

The invention claimed is:
 1. A method for assembling an atomizer for anaerosol delivery device, the method comprising: providing a firstheating terminal, a second heating terminal, and a heating elementwherein the heating element comprises: a wire defining a plurality ofcoils and comprising two contact portions, a center portion, and twoouter portions positioned outside of the contact portions, the twocontact portions and the center portion of the wire defining the heatingelement, wherein the two contact portions define a first coil spacing,the center portion defines a second coil spacing, and the outer portionsdefine a third coil spacing, the third coil spacing being greater thanthe second coil spacing and the second coil spacing being greater thanthe first coil spacing; determining a position of the first heatingterminal and the second heating terminal; determining a position of theheating element; and affixing the heating element to the first heatingterminal and the second heating terminal based on the position of thefirst heating terminal and the second heating terminal and the positionof the heating element.
 2. The method of claim 1, wherein determiningthe position of the first heating terminal and the second heatingterminal comprises determining a midpoint between a first heatingterminal tab and a second heating terminal tab.
 3. The method of claim2, wherein the two contact portions of the heating element comprise afirst contact portion and a second contact portion, and whereindetermining the position of the heating element comprises determining amidpoint between the first contact portion and the second contactportion.
 4. The method of claim 3, further comprising aligning themidpoint between the first heating terminal tab and the second heatingterminal tab with the midpoint between the first contact portion and thesecond contact portion; engaging the first contact portion with thefirst heating terminal tab; and engaging the second contact portion withthe second heating terminal tab.
 5. The method of claim 4, furthercomprising clamping the first heating terminal and the second heatingterminal such that the first heating terminal tab and the second heatingterminal tab are substantially coplanar.
 6. The method of claim 5,wherein clamping the first heating terminal and the second heatingterminal comprises adjusting a spacing between the first heatingterminal and the second heating terminal.
 7. The method of claim 4,wherein affixing the heating element to the first heating terminal andthe second heating terminal comprises directing a laser beam at thefirst heating terminal tab and at the second heating terminal tab. 8.The method of claim 7, wherein directing the laser beam at the firstheating terminal tab and at the second heating terminal tab comprisesdirecting the laser beam at a backside of the first heating terminal taband the second heating terminal tab opposite from the heating element.9. The method of claim 7, further comprising inserting the heatingelement, the first heating terminal, and the second heating terminalinto a substantially sealed chamber before directing the laser beam atthe first heating terminal tab and at the second heating terminal tab.10. The method of claim 1, wherein providing the heating elementcomprises: supplying the heating element from a substantially continuousheating element input; and controlling a tension in the substantiallycontinuous heating element input.
 11. The method of claim 1, furthercomprising coupling the heating element to a liquid transport element.12. The method of claim 11, wherein coupling the heating element to theliquid transport element comprises inserting an end of the heatingelement through the liquid transport element and rotating at least oneof the heating element and the liquid transport element such that theheating element winds about the liquid transport element.
 13. The methodof claim 1, wherein providing the first heating terminal and the secondheating terminal comprises: supplying the first heating terminal from asubstantially continuous first heating terminal input; and supplying thesecond heating terminal from a substantially continuous second heatingterminal input.
 14. The method of claim 1, wherein the plurality ofcoils of the heating element are wound about a liquid transport element.15. The method of claim 14, wherein affixing the heating element to thefirst heating terminal and the second heating terminal comprisesaffixing the contact portions to the first heating terminal and thesecond heating terminal.